Dodge - Dakota 2wd - Workshop Manual - 1996 - 1996

Factory Workshop Manual Make Dodge Model Dakota 2wd Engine and year V6-239 3.9L Magnum (1996) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7 ABS Main Relay: Description and Operation CIRCUIT OPERATION When the Controller, Antilock Brakes (CAB) grounds the ABS power relay on circuit B116, the relay contacts close connecting circuit A1O from the Power Distribution Center (PDC) and circuit B120. Circuit A10 connects to fuse A in the PDC. Circuit A20 from the fuse 4 in the fuse block splices to feed the coil side of the ABS power relay From the ABS power relay, circuit B120 splices to supply voltage to the ABS pump motor and all solenoids in the hydraulic control unit. Circuit B120 also supplies power to the solenoids in the rear wheel anti-lock valve (RWAL). Additionally, circuit B120 provides an input to cavity 34 of the CAB. The input tells the CAB that voltage has been supplied to the pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System Electronic Brake Control Module: Service and Repair With Four Wheel Antilock System Fig 18 Releasing Main Harness Connector Fig 19 Removing Main Harness Connector From Module NOTE: The ABS module is located in the engine compartment attached to the forward side of the front brake anti-lock valve. ABS ELECTRONIC CONTROL MODULE REMOVAL 1. Disconnect upper harness connector from module. 2. Lift connector locking handle to release main harness connector from module. Rotate handle upward to clear connector. 3. Lift connector up and out of retaining lugs on module. 4. Remove screws attaching module to mounting bracket and remove module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 12 Fig 20 ABS Electronic Control Module Installation ABS ELECTRONIC CONTROL MODULE INSTALLATION 1. Position module in mounting bracket and stall module attaching screws. 2. Connect main harness connector to module. Seat connector in module retaining lugs and start connector into module. Then rotate connector locking handle downward into l&ked; position to seat and retain connector. 3. Connect upper harness wires to module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 13 Electronic Brake Control Module: Service and Repair With Rear Wheel Antilock System The ABS module is located behind the passenger's side of the instrument panel, near the defroster duct. 1. Disconnect battery ground cable. 2. Remove passenger side sill plate and cowl cover. 3. Remove control module to cowl attaching screws. 4. Disconnect electrical connector from module, then remove the module. 5. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation CIRCUIT OPERATION The buzzer module sounds an audible warning tone. The tone sounds for seat belt warning and when the ignition key is in the ignition switch while the drivers door is open. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled. Fuses 7 and 16 in the fuse block protect the buzzer module. Fuse 7 powers circuit F32 which connects to the buzzer module. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies power to the fuse block for fuse 7 and circuit F32. Circuit G5 from fuse 16 in the fuse block also provides voltage to the buzzer module when the ignition switch is in the START or RUN positions. The ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 connects to the fuse block. When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26 connects to the buzzer module and the key-in switch. Circuit G16 from the drivers side door jamb switch also connects to the key-in switch. Circuit G13 from the buzzer powers the seat belt warning lamp in the instrument cluster. Circuit Z1 at the instrument cluster provides ground for the lamp. Circuit G1O from the buzzer connects to the seat belt switch. When the seat belt switch closes a path to ground is completed on circuit Z1. Circuit Z1 also grounds the combination buzzer module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 22 Audible Warning Device Control Module: Testing and Inspection - Circuit F32 also powers the stop lamp switch. - Circuit G5 is double crimped at the buzzer module. The G5 branch from the buzzer module splices to power the four-wheel drive lamp and the overdrive lamp, and transmission temperature warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations Key Reminder Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 26 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 27 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 28 Key Reminder Relay: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch lamp and the courtesy lamp. Power for the relay is received on the M1 circuit from the IOD fuse in cavity 2 in the Power Distribution Center (PDC). Circuit M2 provides ground for the time delay relay through the right and left door jamb switches and the headlamp switch. When a door is opened or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on circuit M2. This energizes the relay, causing the contacts to close. When the relay contacts close, power is provided through the relay to circuit M50. The M50 circuit supplies current to the ignition key-in switch lamp and the courtesy lamp. Circuit Z1 provides ground for the lamps. Circuit Z1 also provides ground for the ash receiver lamp and the cigar lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 29 Key Reminder Relay: Testing and Inspection Circuit M1 splices to supply voltage to the glove box lamp, dome lamp, overhead console, power mirror switch, and radio. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position. When the ignition switch is in the RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC), to circuit A21. Circuit A21 is double crimped at a fuse block bus bar and supplies power to the Daytime Running Module (DRL) module. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times. The DRL module receives the vehicle speed sensor input from circuit G7. Circuit G34 provides power for the high beam indicator lamp in the instrument cluster and connects to the DRL module. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 37 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 38 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 46 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 47 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check Powertrain Control Module: Technical Service Bulletins PCM - Cruise Control System Check NO: 08-01-96 GROUP: Electrical DATE: Jan. 19, 1996 SUBJECT: Speed Control Light Flickers and/or Servo Clicks MODELS: 1996 (BR) Ram Truck 1996 (AN) Dakota 1996 (AB) Ram Van/wagon 1996 (XJ) Cherokee SYMPTOM/CONDITION: The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo when the ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF. DISCUSSION: The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignition key to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speed control indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servo receives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systems check when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have any adverse effects on the electrical system within the vehicle. Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normal operation of the system. NOTE: Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 54 Powertrain Control Module: Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 55 Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 56 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 57 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 58 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 59 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 60 Powertrain Control Module: Locations Powertrain Control Module The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment, mounted to the inner fender. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 65 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 78 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture Powertrain Control Module: Description and Operation Architecture Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 82 Powertrain Control Module: Description and Operation Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 83 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: - engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 84 In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 85 Powertrain Control Module: Description and Operation Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 86 Powertrain Control Module: Description and Operation Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 87 Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 88 Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. On-Board Diagnostics ON BOARD DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called "on-board diagnosis." Certain criteria, or "arming conditions," must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 89 Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring - Misfire Detection - EGR System Monitor - Oxygen Sensor Upstream Heater Monitor - Oxygen Sensor Upstream Monitor - Evaporative System Monitor - Catalyst Monitor - Purge Flow Monitor - 02 Heater Downstream Monitor - 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the "Catalyst Monitor" test will not be run unless the "O2 Sensor" test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS - Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: Idle Air Control (IAC) Open/Short Circuit - Generator Field - Torque Converter Clutch (TCC) Solenoid - Fan Relay - A/C Relay - Air Switch / Shift Lock Solenoid - Transmission Relay Output - Automatic Shutdown (ASD) Relay - Fuel Pump Relay - EVAP Purge Solenoid - EGR Solenoid - Ignition Coils - Injector Failure Z2 CIRCUIT CHECKS - Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) - Intake Air Temperature (IAT) Sensor Voltage (high/low) - Engine Coolant Temperature (ECT) Sensor Voltage (high/low) - Throttle Position Sensor (TPS) Voltage (high/low) - Manifold Absolute Pressure (MAP) Sensor 5 Volt Supply Check - Compressed Natural Gas (CNG) Pressure Sensor Voltage (high/low) - CNG Temperature Sensor Voltage (high/low) - Battery Temperature Sensor Voltage (high/low) - Fuel Level Sensor Voltage (high/low) - Transmission Temperature Sensor Voltage (high/low) - Governor Pressure Sensor Voltage (high/low) - Governor Pressure Solenoid (open/short) - ASD Relay Voltage (out of range) - Battery Voltage (too high) - Overdrive Override Switch (fault) - Leak Detection Pump Solenoid (open/short) - 3/4 Shift Solenoid (open/short) - Speed Control Vacuum and Vent Solenoids (open/short) FUNCTIONALITY/RATIONALITY CHECKS - These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present - Crank Sensor Pulses Present - MAP Sensor Output in Range Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 90 - Coolant Temperature in Range - Throttle Position Sensor in Range - Vehicle Speed Sensor Output Correct - Park/Neutral Switch Working - Fuel Level Sensor Output Correct - Transmission Temperature Sensor Output Correct - Transmission Governor Pressure in Range - Output Shaft Speed Sensor Output Correct - AIS Motor Working - Lock-up Solenoid Working - 3/4 Shift Solenoid Working - Governor Pressure Solenoid Working - O2 Sensor 1/1 Output Voltage Low - O2 Sensor 1/2 Output Voltage Low - O2 Sensor 2/1 Output Voltage Low - O2 Sensor 2/2 Output Voltage Low - Charging System Working - Power Steering Switch Working - Thermostat Working - O2 Sensor 1/1 (open circuit or high voltage) - O2 Sensor 1/2 (open circuit or high voltage) - O2 Sensor 2/1 (open circuit or high voltage) - O2 Sensor 2/2 (open circuit or high voltage) Cruise Control CRUISE CONTROL The Powertrain Control Module (PCM) controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation EXHAUST GAS RECIRCULATION The Powertrain Control Module (PCM) controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System FUEL VAPOR RECOVERY SYSTEM (DUTY CYCLE PURGE CONTROL) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the Powertrain Control Module (PCM). The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 Hz signal (at closed throttle) or 10 Hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulse width and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum. Overview OVERVIEW The Powertrain Control Module (PCM) features a multi-processor environment (one 16 bit microcomputer, two 8 bit micro-computers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of up to a ten cylinder engine running in excess of 6,500 RPM. Spark Control SPARK CONTROL The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed. Transmission Control Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 91 TRANSMISSION CONTROL The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling. Sump Pump Temperature Sensing A thermistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 92 Powertrain Control Module: Service and Repair PCM Location REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 96 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 97 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 98 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 106 Except CNG Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 107 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the fuel pump relay. The Powertrain Control Module (PCM) energizes the relay by providing ground for the relay coil on circuit K31. Circuit K31 connects to cavity C19 of the PCM. When the PCM energizes the relay, the contacts close and connect circuit A14 from fuse D in the PDC to circuit A141. Circuit A141 powers the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 108 Fuel Pump Relay: Testing and Inspection Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. Circuit A21 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 112 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 113 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 114 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Airbag Control Module 4 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 121 Airbag Control Module 13 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 124 Air Bag Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 125 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 126 Air Bag Control Module: Description and Operation AIR BAG CONTROL MODULE (ACM) The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F20. Circuits F14 and F20 are connected to separate bus bars in the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. Circuit F20 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. In the START or RUN positions, the ignition switch connects circuit A21 circuit with circuit A1 from fuse C in the PDC. Circuit A21 circuit supplies battery voltage to the fuse block bus bar that feeds circuit F14. Fuse 14 in the fuse block protects circuit F14. When the ignition switch is in the RUN position, it connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies battery voltage to the fuse block bus bar that feeds circuit F20. Fuse 3 in the fuse block protects circuit F20. The ACM is case grounded and has an external dedicated ground, circuit Z6. Circuit Z6 connects to the right fender side shield. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 127 Air Bag Control Module: Testing and Inspection Circuit F14 is double crimped at fuse 14 in the fuse block to feed the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 128 Air Bag Control Module: Service and Repair WARNING: The ACM contains one of the impact sensors which enable the system to deploy the airbag. To avoid accidental deployment, never connect the ACM electrically to the system unless it is bolted to the vehicle. Before beginning any airbag system removal or installation procedures, disconnect and isolate the battery negative (ground) cable from the vehicle battery. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment, and possible personal injury. 1. Disconnect and isolate the battery negative cable. If the airbag is undeployed, wait two minutes for the system capacitor to discharge before further service. Fig 10 Knee Bolster Remove/Install 2. Remove the screws at the lower edge of the knee blocker/steering column cover. 3. Pull the knee blocker/steering column cover down to disengage the slide tabs from the instrument cluster bezel and remove the knee blocker/steering column cover. Fig 11 Gear Selector Indicator Cable Remove/Install 4. If so equipped, disconnect the automatic transmission gear selector indicator cable from the steering column. 5. Remove the two steering column support nuts. 6. Remove the windshield pillar garnish mouldings and the cowl side trim panels. 7. Loosen the instrument panel pivot bolts in the cowl side panels. 8. Remove the five screws from the instrument panel at the base of the windshield and roll the instrument panel down. - Attach a hook from the windshield fence line to the center of the instrument panel mount to hold the instrument panel in position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 129 Fig 12 Airbag Control Module Replacement 9. Unplug the two electrical connectors from the ACM. 10. Remove the four screws holding the ACM to the mounting bracket. 11. Remove the ACM. 12. To install position the ACM with the arrow pointing iorward. 13. Attach the ACM to the mounting bracket with the four screws. Tighten the mounting screws to 3 - 5 Nm (25 - 45 in lb). 14. Connect the wiring to the ACM, making sure both of the connectors are fully-seated and their locking tabs are engaged. 15. Reverse the remaining removal procedures to complete the installation. - Tighten the steering column support nuts to 12 Nm (105 in lb). 16. Do not connect the battery negative cable at this time. See Airbag System Arming for the proper procedure. See: Body and Frame/Interior Moulding / Trim/Dash Panel/Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 134 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 135 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 136 Starter Relay: Testing and Inspection Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 147 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 148 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 154 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 155 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 156 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 160 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 161 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Intermittent Wipe Module Remove/Install The Intermittent Wiper Control Unit is located to the right of the steering column on the back side of the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the left door lock switch is moved to the LOCK position, voltage is supplied on circuit P35 to the LOCK bus bar inside the right door switch . Battery voltage is passed through the right door switch to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the left door lock switch is moved to the UNLOCK position, voltage is supplied on circuit P36 to the UNLOCK bus bar inside the right door switch. Battery voltage is passed through the right door switch to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 172 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the right door switch is moved to the LOCK position, voltage is supplied to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the right door switch is moved to the UNLOCK position, voltage is supplied to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on Z1 circuit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 173 Power Door Lock Switch: Testing and Inspection - Check fuse G in the PDC. - Check fuse 5 in the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 182 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 183 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 188 39 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 189 43 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 190 45 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 191 47 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 192 51 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 193 55 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 194 57 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 195 59 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 196 63 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 197 67 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 198 69 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 199 71 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 200 173 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 201 177 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 202 179 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 203 181 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 204 187 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 205 191 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 206 193 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 207 195 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 208 201 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 209 205 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 210 207 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 211 209 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 212 256 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 1 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 215 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle. 2. Remove front wheels. 3. Remove disc brake caliper and support to frame using suitable wire. 4. Remove bolts attaching sensor to splash shield and steering knuckle. Retain special sensor bolts for installation. 5. Remove wire clamps and wire from control arm and steering knuckle. 6. Disconnect sensor harness connector and work sensor wire through fender panel, then remove sensor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque special sensor bolt to 13-18 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 218 Wheel Speed Sensor: Service and Repair Rear With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 219 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 225 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 226 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 227 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 228 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch from mounting bracket, then disconnect switch from wiring harness. 2. Using a suitable ohmmeter, ensure switch continuity is as follows: a. With switch plunger released, continuity should exist between pins 5 and 6. b. With switch plunger depressed, continuity should exist between pins 1 and 2 and between pins 3 and 4. 3. If switch continuity is as specified, switch is satisfactory; if not, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 236 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 237 Speed Control Switch: Testing and Inspection 1. Disconnect battery ground cable. 2. Remove speed control switch. Speed Control Switch Continuity 3. Inspect switch continuity as shown. 4. If continuity is not as specified, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 238 Speed Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 243 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation Outside Temperature Display Sensor: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 251 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 252 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes Brake Light Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29, the Controller, Anti-Lock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 connects to cavity 9 of the CAB, the stop lamp switch and the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 261 Brake Light Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 262 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column opening cover. 3. Remove screws attaching air duct to air conditioning/defroster and move to gain access to switch bracket. 4. Unseat wire harness retainer from pedal support and remove retainer, then remove switch bracket nut and washer. 5. Push brake pedal forward then work switch and bracket out of support. 6. Disconnect switch wires, then remove switch and bracket as assembly. 7. Reverse procedure to install, noting the following: a. Torque bracket retaining nut to 60 inch lbs. b. Ensure bracket tang seats in support. c. Check switch operation before attaching air duct and steering column cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position > Page 267 Headlamp Switch: Description and Operation Headlamp Switch in the PARKING LAMP Position CIRCUIT OPERATION Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker that connects circuit A3 to circuit L20. In the OFF and PARK positions, the headlamp switch feeds circuit L20 which connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L20 to circuit L3. Circuit L3 feeds the high beam of the headlamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 268 Headlamp Switch: Service and Repair 1. Disconnect ground cable from battery. Steering Column Cover 2. Remove lower cover and instrument cluster bezel. 3. Remove five switch bezel screws, then pull switch and bezel assembly to rear and disconnect wiring. 4. Remove and discard nut, then push release button on right side of switch and pull headlamp knob out. 5. Separate bezel from switch and mounting assembly, then remove spanner nut and remove headlamp switch from mounting bracket. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Page 272 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 278 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 279 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 283 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 286 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 287 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 288 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 292 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 293 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 294 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 295 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 299 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 302 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 305 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 306 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation CIRCUIT OPERATION The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit G8 from the level sensor connects to cavity C26 of the Powertrain Control Module (PCM). Circuit G8 provides the fuel level input to the PCM. Circuit K4 provides ground for the signal. Circuit Z1 provides the ground path for the fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 313 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 314 Intake Air Temperature Sensor: Description and Operation CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig. 68 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. NOTE: for additional testing information, see Testing and Inspection/Test TC-57A or Test TC-58A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 317 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 318 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Remove air cleaner assembly. Fig. 68 Intake Manifold Air Temperature Sensor 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 322 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 323 Manifold Pressure/Vacuum Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 324 Manifold Pressure/Vacuum Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 325 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 86 MAP Sensor L-Shaped Rubber Fitting The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 330 Oxygen Sensor: Locations Oxygen Sensor(s) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views Oxygen Sensor: Connector Views Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views > Page 333 JTEC O2 Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 334 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information - Along with supplying voltage to the ASD relay contacts, circuit A14 supplies voltage to the contact side of the fuel pump relay. - Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 337 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter (Fig. 62). Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 338 Oxygen Sensor: Service and Repair Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 345 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 346 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 347 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 348 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 352 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 360 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 373 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 375 Vehicle Speed Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuits T33 and K7. Circuit T33 connects to circuit K7. Circuit T33 connects to cavity B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 376 Vehicle Speed Sensor: Testing and Inspection Circuit G7 splices to the speedometer and Daytime Running Lamps (DRL) module. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 377 Vehicle Speed Sensor: Service and Repair Fig. 18 Vehicle Speed Sensor Location - 2WD REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt. Fig. 105 Sensor Removal/Installation 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter. Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 N.m (20 in. lbs.) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 382 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 383 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 384 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 385 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 390 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 393 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 394 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 395 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 399 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 402 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 405 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 406 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 410 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 411 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 412 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 413 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 419 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 420 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 421 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 422 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 423 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 424 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 425 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 426 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 427 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 428 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 429 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 430 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 431 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Impact Sensor Location Impact Sensor Location Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 436 Impact Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 437 Impact Sensor: Diagrams Left Impact Sensor Connector Right Impact Sensor Connector Impact Sensor 4 Way Harness Connector -- To Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 438 Impact Sensor 4 Way Harness Connector -- To Sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 439 Impact Sensor: Description and Operation DESCRIPTION Two impact sensors and a safing sensor provide verification of the direction and severity of an impact. The safing sensor is located inside the Airbag Control Module (ACM), which is mounted to a bracket on the floor transmission tunnel, under the instrument panel. The two impact sensors are mounted on the inner fender extension panels behind the grille opening reinforcement, on the left and right sides of the vehicle. OPERATION The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The safing sensor is an accelerometer that senses the rate of deceleration. The sensors are calibrated for the specific vehicle, and are sensitive to both the severity and the direction of an impact. The microprocessor in the ACM monitors the sensor signals. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the driver side airbag. REPLACEMENT The impact sensors and safing sensor cannot be repaired or adjusted and, if faulty or damaged, they must be replaced. The impact sensors are available for service replacement. The safing sensor is only serviced as part of the ACM. CIRCUIT OPERATION The airbag system uses two impact sensors. Circuits R47 and R49 connect from the left sensor to the Airbag Control Module (ACM). Circuits R46 and R48 connect the right sensor to the ACM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 440 Impact Sensor: Service and Repair Fig 8 Battery Holddown Remove/Install LEFT SIDE 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed wait two minutes for the system capacitor to discharge before further service. 2. Remove the battery holddown and move the battery rearward. 3. Unplug the connector from the left impact sensor. Fig 9 Impact Sensor -- Typical 4. Remove the three nuts holding the left sensor to the closure panel support and remove the sensor. 5. To install mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb) . 6. Connect the left sensor wiring to the connector on the body of the sensor. 7. Install the battery holddown strap. Be certain the battery is properly positioned in the battery tray. Tighten the holddown bolts to 2.2 N.m (20 in lb). 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Body and Frame/Interior Moulding / Trim/Dash Panel/Air Bag(s) Arming and Disarming/Service and Repair RIGHT SIDE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 441 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed, wait two minutes for the system capacitor to discharge before further service. 2. Pull the air cleaner fresh air inlet tube off of the radiator support. 3. Unplug the connector from the right impact sensor. 4. Remove the three nuts holding the right sensor to the closure panel support and remove the sensor. 5. To install, mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb). 6. Connect the right sensor wiring to the connector on the body of the sensor. 7. Install the air cleaner inlet tube to the radiator support. 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Body and Frame/Interior Moulding / Trim/Dash Panel/Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 446 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 447 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 454 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 455 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 456 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 457 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 461 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 462 Neutral Safety Switch: Description and Operation When closed, the case-grounded PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 463 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 464 Neutral Safety Switch: Service and Repair 1. Raise and support vehicle, then position drain pan under switch. 2. Disconnect switch wires and remove switch from case. 3. Ensure switch operating lever fingers center in case opening for switch when shift lever is in Park and Neutral positions. 4. Install switch and new seal. Torque switch to 25 ft. lbs. 5. Connect switch wires, lower vehicle and check transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 475 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 484 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 490 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 494 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 495 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 499 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 504 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 505 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 509 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 515 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation Power Window Switch: Description and Operation Driver Side Switch Operation CIRCUIT OPERATION Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation > Page 521 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 522 Power Window Switch: Testing and Inspection - Check fuse E in the PDC. - Check the circuit breaker in cavity 2 of the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation CIRCUIT OPERATION Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster. When the low washer fluid switch closes, it connects circuits G29 and Z1. Circuit Z1 provides a ground path, illuminating the warning lamp. Circuit Z1 also provides ground for the windshield washer pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Page 530 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Two Speed Wiper Switch Continuity Chart Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 534 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 535 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications Caster Angle, Degrees Limits ................................................................................................................................................... .............................................. +1/2 to +2 1/2 [01] Desired ................................................................... .................................................................................................................................................. +1 1/2 Camber Angle, Degrees Limits ................................................................................................................................................... ................................................................... 0 to +1 Desired ................................................................ ....................................................................................................................................................... + 1/2 Toe-In, Inch ......................................................................................................................................... .......................................................................... + 1/8 Ball Joint Wear, Inch ....................................... ...................................................................................................................................................... 0.020 [02] [01] -- Maximum left to right differential should not exceed +1 1/4. [02] -- For inspection procedure, refer to Ball Joint Inspection @ Steering & Suspension/ Suspension/ Ball Joint/ Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 540 Alignment: Service and Repair CASTER & CAMBER 1. Remove all foreign material from exposed threads of pivot bar adjusting nuts. Fig. 1 Loosening Pivot Bar Adjusting Nuts 2. Record initial camber and caster readings before loosening pivot bar adjusting nuts. 3. Moving only rear pivot of upper control arm in or out will greatly affect caster while changing camber only slightly. Moving front pivot of upper control arm in or out will greatly affect camber while changing caster only slightly. 4. Caster should be held as nearly equal as possible on both wheels. 5. Camber settings should be held as close as possible to desired specifications. 6. After adjusting, torque tighten pivot bar attaching nuts to 155 ft. lbs. TOE-IN 1. Start engine, turn wheels both ways before straightening, then secure steering wheel with wheels pointed straight ahead. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 541 Fig. 2 Toe Adjustment. 2WD Models Fig. 3 Toe Adjustment 4WD Models 2. Loosen tire rod adjustment sleeve camp bolts or nut. 3. Adjust toe-in by turning sleeves. Each wheel should be adjusted 1/2 total specification to ensure steering wheel being centered. 4. Torque locknut to 55 ft. lbs. or clamp bolts to 17 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 547 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 550 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 551 5. Connect vehicle fuel line into adapter tool 6923. Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T". 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 9. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 1988 - 1996 3.9L (238) Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 1988 - 1996 3.9L (238) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 574 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 575 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 576 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 577 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 578 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 579 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 585 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 586 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 587 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 588 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 589 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 590 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 591 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 592 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 593 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Description and Operation Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 606 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 607 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 608 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 609 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 610 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Oil or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 611 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced, or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 612 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 613 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 0.89 mm (0.035 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum compression pressure should be 100 psi. Maximum variation between cylinders is 25 percent. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments These engines use hydraulic lifters. No provision for adjustment is provided. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Fig. 19 Serpentine Drive Belt Routing Refer to Fig.19 for serpentine drive belt routing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 623 Drive Belt: Service and Repair Fig. 20 Automatic Belt Tensioner Assembly The automatic tensioner is equipped with an indexing arrow on the back of tensioner housing. If a new belt is being installed, arrow must be within approximately 1/8 inch of point B indexing mark. If an old belt is being used, it must not pass indexing point marked A, Fig.20. REMOVAL Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 624 Fig. 21 Serpentine Drive Belt Removal 1. Attach a suitable wrench to automatic tensioner pulley mounting bolt, Fig.21. 2. Rotate tensioner assembly clockwise until tension has been relieved. 3. Remove belt from idler puller, then from vehicle. INSTALLATION CAUTION: Serpentine belt must be routed correctly. If routed incorrectly water pump will rotate in wrong direction and engine will overheat. 1. Position drive belt over all pulleys except idler pulley. 2. Attach a suitable wrench to automatic tensioner pulley mounting bolt. 3. Rotate wrench clockwise, place belt over idler pulley, then allow tensioner to rotate back into place. Ensure belt is properly seated on all pulleys. 4. Check belt indexing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair Crankcase Filter: Service and Repair CRANKCASE INLET AIR (BREATHER) FILTER Crankcase Inlet Air (Breather) Filter The crankcase inlet air (breather) cleaner must be kept clean and lubricated. At the recommended interval, remove the filter and wash it thoroughly in kerosene, or similar solvent. Lubricate or wet the filter by inverting the filter and filling with SAE 30 engine oil. Filter must then be thoroughly drained. More frequent service may be necessary for vehicles operated extensively on short run, stop and go, or extended engine idle service. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 644 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 645 Coolant: Specifications Engine ................................................................................................................................................. ............................................................... 3.9L/V6-238 Coolant Capacity Less A/C, Qts. ......................................................................................................... .................................................................................................... 14 [03] With A/C, Qts. ..................... .............................................................................................................................................................. ......................... 14 [03] Radiator Cap Relief Pressure, Lbs. ..................................................................................................... .......................................................................... 14-18 Thermo. Opening Temp., °F .......................... .............................................................................................................................................................. .... 192 Fuel Tank, Gals. ...................................................................................................................... ........................................................................................ [01] Engine Oil Refill, Qts. [04] ................... .............................................................................................................................................................. ................. 4 Transmission Oil 4 Speed, Pints ......................................................................................................... ............................................................................................................. -- 5 Speed, Pints [02] ............. .............................................................................................................................................................. ................................. 4.2 Auto. Trans., Qts. [02] ................................................................................. ..................................................................................................... 4.75-5.5 [05] [01] -- Standard fuel tank, 15 gals., Optional fuel tank, 22 gals. [02] -- Transfer case, 2.5 pints. [03] -- With 26 inch maximum cooling radiator, 14.3 quarts. [04] -- Includes oil filter. [05] -- Depending on type & size of internal cooler, length & diameter of cooler lines, or use of auxiliary cooler. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 646 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 651 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 652 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 653 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 654 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 655 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Dry Refill Capacity 47RH ..................................................................................................................... ........................................................ 14.6L (15.4 Qt) Initial Refill Capacity 46RH ................................ .............................................................................................................................................. 4.9L (5.7 Qt) Initial Refill Capacity All others ...................................................................................................... ................................................................. 4.4L (5.2 Qt) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 658 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Automatic Transmission Fluid Mopar ATF Plus 4, Type 9602 automatic transmission fluid is the recommended fluid for Chrysler automatic transmissions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid AX-15 ................................................................................................................................................... ........................................................ 3.1L (6.6 Pints) NV3500 ............................................................. ............................................................................................................................................ 2.0L (4.2 Pints) NV4500 ..................................................................................................................................... .................................................................... 3.8L (8.0 Pints) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 663 Fluid - M/T: Fluid Type Specifications NV3500 ................................................................................................................................................ .......................................................... 2.0 L (2.1 qts.) AX15 .................................................................................................................................................... .......................................................... 3.1 L (3.3 qts.) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front 4WD 7 1/4" ................................................................................................................................. .................................................................. 1.4L (3.0 Pints) Dana 44 ................................................... ...................................................................................................................................................... 2.7L (5.6 Pints) Dana 60 .............................................................................................................................. ........................................................................... 3.0L (6.3 Pints) Rear 7 1/4" ..................................... .............................................................................................................................................................. .......... 1.4L (3.0 Pints) 8 1/4" ............................................................................................................... .............................................................................................. 2.1L (4.4 Pints) 9 1/4" ........................... .............................................................................................................................................................. .................... 2.2L (4.7 Pints) Dana 60 ................................................................................................. ........................................................................................................ 3.0L (6.3 Pints) Dana axles, lubricant level in axle must be 1/2 - 1" below fill plug opening. All with limited slip, add one container of MOPAR Trac-Loc additive. Rear Dana axles with limited slip include 0.2 L (0.4 pts) friction modifier additive ex Dana 80 4WD application include 0.3 L (0.6 pts) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 668 Fluid - Differential: Fluid Type Specifications Rear Differential Fluid Type 7 1/4 ..................................................................................................................................................... ............................................................. SAE 80W-90 8 1/4 inch Axle ..................................................................................................................................... ............................................................ SAE 80W-90 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil 2.5L Without Filter Change .................................................................................................................. ............................................................ 3.8L (4.0 Qt) 3.9L Without Filter Change ................................ .............................................................................................................................................. 3.3L (3.9 Qt) 5.2L, 5.9L Without Filter Change ................................................................................................... .................................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 673 Engine Oil: Fluid Type Specifications ENGINE OIL SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. - SAE 30 = single grade engine oil. - SAE 10W-30 = multiple grade engine oil. API QUALITY CLASSIFICATION The API Service Grade specifies the type of performance the engine oil is intended to provide. The API Service Grade specifications also apply to energy conserving engine oils. Use engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. MOPAR engine oils conform to all of these service grades. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 678 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 679 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 680 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Capacity 2.0 lb (US) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 685 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant type R134a Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications With Compressor Model, SD7H15 Component Oil Capacity ...................................................................................................................... .................................................................. Ounces Total Capacity ..................................................... ........................................................................................................................................................ 7.75 Compressor ......................................................................................................................................... ....................................................................... -- Condenser ................................................................ .................................................................................................................................................. 1 Evaporator ........................................................................................................................................... ....................................................................... 2 Filter-Drier ................................................................. ................................................................................................................................................ 4 Line .. .............................................................................................................................................................. ............................................................ -- Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. On vehicles with disc brakes the brake pedal will require more pumping and frequent checking of fluid level in master cylinder during bleeding operation. Never use brake fluid that has been drained from hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and that the pad assemblies are properly seated. Before driving the vehicle, check brake operation to be sure that a firm pedal has been obtained. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 693 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Combination valve. 3. Rear anti-lock valve. 4. Front anti-lock valve. 5. Left rear wheel. 6. Right rear wheel. 7. Right front wheel. 8. Left front wheel. W/ Rear Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Front anti-lock valve. 3. Rear anti-lock valve. 4. Right rear wheel. 5. Left rear wheel. 6. Right front wheel. 7. Left front wheel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 694 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) 1. Install pressure bleeding tank part No. 3495-B, or equivalent, to master cylinder, then install metering valve hands off tool No. C-4121, or equivalent, to valve stem of metering valve. 2. On models equipped with RWAL, proceed as follows: a. Connect one end of a suitable hose to bleeder valve on RWAL hydraulic valve and submerge other end in a glass container partially filled with clean brake fluid. b. Open bleeder valve on RWAL hydraulic valve, and keep open until clear bubble free fluid flows from hose. 3. On all models, bleed one wheel at a time in order as follows: a. Right rear wheel. b. Left rear wheel. c. Right front wheel. d. Left front wheel. 4. Keep bleeder screws open until clear bubble free fluid flows from hose. 5. Repeat bleeding procedure if system indicator light stays On or if pedal feels spongy. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 699 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 704 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 709 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 722 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Fuse: Connector Views Fuse/Fuse Block Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 726 Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 728 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 729 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 733 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 734 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Fuse panel is located under left side of instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 742 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 745 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 754 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 755 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 759 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 762 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 763 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 769 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 770 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Fig. 1 SRI Lamp Location The lamp is displayed on the instrument panel as the MAINT REQ'D lamp Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Locations > Page 775 Emissions Maintenance Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation OPERATION The Powertrain Control Module (PCM) performs an on-board Diagnostic (OBD) check of the EGR system on all California vehicles. The diagnostic system uses the electronic EGR Transducer (EET) for the system tests. The OBD check activates only during selected engine/driving conditions. When the conditions are met, the PCM energizes the EET solenoid to disable the EGR. the PCM checks for a change in the oxygen sensor signal. If the air/fuel mixture goes lean, the PCM will attempt to enrich the mixture. The PCM registers a Diagnostic Trouble Code (DTC) if the EGR system has failed or degraded. After registering a DTC, the PCM turns the Malfunction Indicator Lamp (MIL) ON. The MIL indicates the need for immediate service. If a malfunction is indicated by the MIL and a DTC for the EGR system was set, check for proper operation of the EGR system. If the EGR system tests properly, check the system using the DRB II scan tool. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Locations Fig. 2 Dakota Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Tires: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments 1. Tighten adjusting nut to specifications while rotating hub. 2. Stop rotation and loosen adjusting nut, then tighten nut finger tight and install locknut and new cotter pin. 3. Endplay should be: 0.000-0.003 inch on 1995 models. 0.001-0.003 inch on 1996 models. 4. Clean grease cap, coat (do not fill) inside with wheel bearing grease and install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Locations Fig. 2 Dakota Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Minimum compression pressure should be 100 psi. Maximum variation between cylinders is 25 percent. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt 35 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications All Specifications Given In Inches Unless Otherwise Noted. Camshaft Journal Diameter ................................................................................................................. ........................................................................... [06] Camshaft Bearing Clearance ........................... ..................................................................................................................................... 0.0010 0.0030 [05] Camshaft Endplay ............................................................................................................ ............................................................................. 0.0020 - 0.0100 Footnotes: [05] -- Service limit, 0.005 inch. [06] -- No. 1, 1.998 - 1.999 inches; No. 2, 1.982 - 1.983 inches; No. 3, 1.951 - 1.952 inches; No. 4, 1.5605 - 1.5615 inches. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement 1. With engine removed from vehicle, remove intake manifold, cylinder head covers, timing chain cover, timing chain, rocker arms and rocker shaft. 2. Remove pushrods and lifters, identifying each for assembly reference. 3. Remove distributor, then lift out oil pump and distributor driveshaft. 4. Remove camshaft thrust plate. Note location of chain oil tab. 5. Install a long bolt into front of camshaft and remove camshaft being careful not to damage bearings with lobes. 6. Reverse procedure to install. Tighten thrust plate bolt and camshaft bolt to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 811 Camshaft: Service and Repair Shaft Prealignments NOTE: Before installing the distributor, the oil pump drive shaft must be aligned to number one cylinder. 1. Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. 2. When in this position, the timing mark of vibration damper should be under "0" on the timing indicator. 3. Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The slot on top of oil pump shaft should be aligned towards the left front intake manifold attaching bolt hole. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications All Specifications Given In Inches Unless Otherwise Noted. Lifter Bore Diameter ............................................................................................................................ ................................................ 0.9051 - 0.9059 [07] Lifter Diameter ................................................... .................................................................................................................................. 0.9035 - 0.9040 [07] Lifter To Bore Clearance .............................................................................................................. ................................................................ 0.0011 - 0.0024 Footnote: [07] -- Oversize lifters (0.008 inch) indicated by diamond stamping on top pad, front of engine, and a flat ground on outside surface of each oversize lifter bore. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 818 Rocker Arm Assembly: Service and Repair 1. Disconnect spark plug wires, then cylinder head cover and gasket. 2. Reverse procedure to install, rotating crankshaft until ``V6'' or ``V8'' mark lines up with TDC mark on timing chase case cover (147° after TDC). Tighten bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications All Specifications Given In Inches Unless Otherwise Noted. Bearing Clearance Main Bearings ...................................................................................................................................... ..................................................................... [07] Connecting Rod Bearings ....................................... .................................................................................................................................. 0.0005 - 0.0022 Thrust Bearing ..................................................................................................................................... ............................................. 0.0020 - 0.0070 [08] Footnotes: [07] -- Preferred: No. 1, 0.0005 - 0.0015 inch; Nos. 2, 3 & 4, 0.0005 - 0.0020 inch. Service limit: No. 1, 0.0015 inch; Nos. 2, 3 & 4, 0.0025 inch. [08] -- Service limit, 0.010 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 823 Connecting Rod Bearing: Service and Repair Crankshaft main bearings are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are not interchangeable. Bearings are available in standard size and undersizes of 0.001, 0.002, 0.003, 0.010 and 0.012 inch. Lower main bearing halves of No. 1 and 3 are interchangeable. Upper and lower No. 2 bearing halves are flanged to carry thrust loads and are not interchangeable with any other bearing halves. Install connecting rod bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file rods or bearing caps. Ensure V-groove in lower bearing shell is in line with V-groove in cap parting face. Install shells with tangs in rod and cap machined grooves. Bearings are available in are available in 0.001, 0.002, 0.003, 0.010 and 0.012 inch undersize. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Nut Torque 45 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 828 Connecting Rod: Specifications Connecting Rod Specifications All Specifications Given In Inches Unless Otherwise Noted. Connecting Rods Pin Bore Diameter ............................................................................................................................... ..................................................... 0.9819 - 0.9834 Side Clearance .................................................... ...................................................................................................................................... 0.0060 0.0140 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 829 Connecting Rod: Service and Repair Identify connecting rods and caps by cylinder before removing. Remove pistons and connecting rods from top of cylinder only, with crankshaft centered at bottom dead center. Do not nick crankshaft journals. Fig. 16 Piston Measurements It is important that pistons be checked for taper and elliptical shape, Fig.16. Before installing pistons and connecting rods, ensure compression ring gaps are staggered so that neither is inline with oil ring rail gap. Install piston and connecting rod assembly into engine with notch or groove on piston top facing front of engine and larger chamfer on connecting rod bore facing crankshaft journal fillet. Fit rods one bank at a time; do not alternate from side to side. Connecting rods and pistons are not interchangeable between banks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications All Specifications Given In Inches Unless Otherwise Noted. Bearing Clearance Main Bearings ...................................................................................................................................... ..................................................................... [07] Connecting Rod Bearings ....................................... .................................................................................................................................. 0.0005 - 0.0022 Thrust Bearing ..................................................................................................................................... ............................................. 0.0020 - 0.0070 [08] Footnotes: [07] -- Preferred: No. 1, 0.0005 - 0.0015 inch; Nos. 2, 3 & 4, 0.0005 - 0.0020 inch. Service limit: No. 1, 0.0015 inch; Nos. 2, 3 & 4, 0.0025 inch. [08] -- Service limit, 0.010 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 833 Crankshaft Main Bearing: Service and Repair Crankshaft main bearings are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are not interchangeable. Bearings are available in standard size and undersizes of 0.001, 0.002, 0.003, 0.010 and 0.012 inch. Lower main bearing halves of No. 1 and 3 are interchangeable. Upper and lower No. 2 bearing halves are flanged to carry thrust loads and are not interchangeable with any other bearing halves. Install connecting rod bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file rods or bearing caps. Ensure V-groove in lower bearing shell is in line with V-groove in cap parting face. Install shells with tangs in rod and cap machined grooves. Bearings are available in are available in 0.001, 0.002, 0.003, 0.010 and 0.012 inch undersize. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Rebuild Specifications Crankshaft: Specifications Rebuild Specifications All Specifications Given In Inches Unless Otherwise Noted. Crankshaft Main Bearing Journal Diameter ........................................................................................................... ..................................................... 2.4995 - 2.5005 Connecting Rod Journal Diameter ...................... .......................................................................................................................................... 2.124 2.125 Out Of Round All [01] ................................................................................................................ .............................................................................. 0.001 Taper All [01] .............................................. ............................................................................................................................................................. 0.001 Bearing Clearance Main Bearings ...................................................................................................................................... ..................................................................... [07] Connecting Rod Bearings ....................................... .................................................................................................................................. 0.0005 - 0.0022 Thrust Bearing ..................................................................................................................................... ............................................. 0.0020 - 0.0070 [08] Footnotes: [01] -- Maximum. [07] -- Preferred: No. 1, 0.0005 - 0.0015 inch; Nos. 2, 3 & 4, 0.0005 - 0.0020 inch. Service limit: No. 1, 0.0015 inch; Nos. 2, 3 & 4, 0.0025 inch. [08] -Service limit, 0.010 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Rebuild Specifications > Page 838 Crankshaft: Specifications Crankshaft Main Bearing Caps 85 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications All Specifications Given In Inches Unless Otherwise Noted. Piston Diameter (Std.) ......................................................................................................................... ................................................................................ -- Piston Clearance ............................................. .............................................................................................................................................. 0.0005 0.0015 Piston Pin Diameter ................................................................................................................. ..................................................................... 0.9841 - 0.9843 Piston Pin To Piston Clearance ........................................................................................................................................................ 0.00025 - 0.00075 [07] Piston Ring End Gap [01] Compression ....................................................................................................................................... ...................................................... 0.0100 - 0.0200 Oil ....................................................................... ...................................................................................................................................... 0.0100 0.0500 Piston Ring Side Clearance Compression ....................................................................................................................................... ...................................................... 0.0015 - 0.0030 Oil ....................................................................... ...................................................................................................................................... 0.0020 0.0080 Footnotes: [01] -- Minimum. [07] -- Standard: Top, 0.0010 - 0.0020 inch; second, 0.0011 - 0.0021 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 842 Piston: Service and Repair Identify connecting rods and caps by cylinder before removing. Remove pistons and connecting rods from top of cylinder only, with crankshaft centered at bottom dead center. Do not nick crankshaft journals. Fig. 16 Piston Measurements It is important that pistons be checked for taper and elliptical shape, Fig.16. Before installing pistons and connecting rods, ensure compression ring gaps are staggered so that neither is inline with oil ring rail gap. Install piston and connecting rod assembly into engine with notch or groove on piston top facing front of engine and larger chamfer on connecting rod bore facing crankshaft journal fillet. Fit rods one bank at a time; do not alternate from side to side. Connecting rods and pistons are not interchangeable between banks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications All Specifications Given In Inches Unless Otherwise Noted. Piston Ring End Gap [01] Compression ....................................................................................................................................... ...................................................... 0.0100 - 0.0200 Oil ....................................................................... ...................................................................................................................................... 0.0100 0.0500 Piston Ring Side Clearance Compression ....................................................................................................................................... ...................................................... 0.0015 - 0.0030 Oil ....................................................................... ...................................................................................................................................... 0.0020 0.0080 Footnote: [01] -- Minimum. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments These engines use hydraulic lifters. No provision for adjustment is provided. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 856 Rocker Arm Assembly: Service and Repair 1. Disconnect spark plug wires, then cylinder head cover and gasket. 2. Reverse procedure to install, rotating crankshaft until ``V6'' or ``V8'' mark lines up with TDC mark on timing chase case cover (147° after TDC). Tighten bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Bolts 95 in.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications All Specifications Given In Inches Unless Otherwise Noted. Valve Guides Inside Diameter ................................................................................................................................... ...................................................... 0.3130 - 0.3140 Stem To Guide Clearance .................................. .................................................................................................................................. 0.001 - 0.003 [09] Footnote: [09] -- Maximum allowable before reconditioning (check by rocking method), 0.0170 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications All Specifications Given In Inches Unless Otherwise Noted. Valve Seats Seat Angle, degrees ............................................................................................................................ ....................................................... 44 1/4 - 44 3/4 Seat Width Intake ................................................................................................................................................... ................................................... 0.040 - 0.060 Exhaust ..................................................................... .............................................................................................................................. 0.060 - 0.080 Runout ................................................................................................................................................. ...................................................................... 0.003 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications All Specifications Given In Inches Unless Otherwise Noted. Free length .......................................................................................................................................... ........................................................................... 1.967 Maximum straightness deviation ................... .............................................................................................................................................................. .......... - Installed height ....................................................................................................................... ....................................................................................... 1.640 Pressure pounds @ inches Closed ................................................................................................................................................. ............................................................. 85 @ 1.640 Open .................................................................. ............................................................................................................................................ 200 @ 1.212 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 869 Valve Spring: Service and Repair 1. With cylinder head removed, compress valve springs using valve spring compressor tool No. C-3422-A, C-3422-B and MD-998772-A, or equivalents. 2. Remove valve retaining locks, valve spring retainers, valve stem cup seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to valve guides. Identify valves for installation reference. 4. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications All Specifications Given In Inches Unless Otherwise Noted. Stem Diameter Intake ................................................................................................................................................... ........................................................... 0.3120 [09] Exhaust ................................................................. .......................................................................................................................................... 0.3120 [09] Installed Height .................................................................................................................................... .............................................................................. -- Valve Recess .................................................... .............................................................................................................................................................. ..... -- Maximum Tip Refinish ................................................................................................................ ................................................................................... [08] Face Angle, degrees ................................ ....................................................................................................................................................... 43 1/4 - 43 3/4 Margin [01] Intake ................................................................................................................................................... ...................................................................... 0.047 Exhaust ............................................................... ....................................................................................................................................................... 0.047 Valve Clearance Intake ................................................................................................................................................... ...................................................................... [06] Exhaust .................................................................. ..................................................................................................................................................... [06] Footnotes: [06] - Hydraulic lash adjusters. [08] Valves may be ground to correct installed height unless they are equipped w/rotators. If valves are equipped w/rotators, do not grind stem tips. [09] - Standard diameter. Valve should be replaced if wear exceeds 0.002 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 873 Valve: Service and Repair 1. With cylinder head removed, compress valve springs using valve spring compressor tool No. C-3422-A, C-3422-B and MD-998772-A, or equivalents. 2. Remove valve retaining locks, valve spring retainers, valve stem cup seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to valve guides. Identify valves for installation reference. 4. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Fig. 19 Serpentine Drive Belt Routing Refer to Fig.19 for serpentine drive belt routing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 878 Drive Belt: Service and Repair Fig. 20 Automatic Belt Tensioner Assembly The automatic tensioner is equipped with an indexing arrow on the back of tensioner housing. If a new belt is being installed, arrow must be within approximately 1/8 inch of point B indexing mark. If an old belt is being used, it must not pass indexing point marked A, Fig.20. REMOVAL Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 879 Fig. 21 Serpentine Drive Belt Removal 1. Attach a suitable wrench to automatic tensioner pulley mounting bolt, Fig.21. 2. Rotate tensioner assembly clockwise until tension has been relieved. 3. Remove belt from idler puller, then from vehicle. INSTALLATION CAUTION: Serpentine belt must be routed correctly. If routed incorrectly water pump will rotate in wrong direction and engine will overheat. 1. Position drive belt over all pulleys except idler pulley. 2. Attach a suitable wrench to automatic tensioner pulley mounting bolt. 3. Rotate wrench clockwise, place belt over idler pulley, then allow tensioner to rotate back into place. Ensure belt is properly seated on all pulleys. 4. Check belt indexing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Adjustments Drive Belt Tensioner: Adjustments Belt tension is automatically adjusted. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Adjustments > Page 883 Drive Belt Tensioner: Service and Repair Fig. 21 Serpentine Drive Belt Removal 1. Attach a suitable wrench to automatic tensioner pulley mounting bolt, Fig.21. 2. Remove drive belt as outlined under ``Drive Belt Replacement''. 3. Disconnect wiring and secondary cable from ignition coil, then remove ignition coil from mounting bracket. 4. Remove tensioner assembly from mounting bracket, then remove pulley bolt and remove pulley from tensioner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Adjustments > Page 884 Fig. 20 Automatic Belt Tensioner Assembly 5. Reverse procedure to install, aligning indexing tab located on back of tensioner to slot in mounting bracket, Fig.20. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount 1. Disconnect battery ground cable, then raise hood and position fan to ensure clearance for radiator top tank and hose. 2. Install suitable engine lifting equipment. 3. Raise and support vehicle. Fig. 2 Rear Engine Mount Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 889 Fig. 2 Left Front Engine Mount 4. Remove attaching bolts and washers from front support insulator assembly and engine strut, Fig.1 and Fig.2. 5. Move strut out of way and remove through bolts, then lift engine enough to remove insulator assembly. 6. Raise engine enough to remove mount. 7. Reverse procedure to install. Tightening bolts and nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 890 Engine Mount: Service and Repair Rear Mount With Automatic Transmission 1. Disconnect battery ground cable, then raise and support vehicle. 2. Support transmission with transmission jack. Fig. 3 Tear Engine Mount. 2WD W/automatic Transmission 3. Remove engine support bracket through bolt, Fig.3. 4. Raise transmission and engine slightly and remove stud nuts attaching insulator to crossmember. 5. Remove engine mount. 6. Reverse procedure to install. Tighten nuts and bolts to specifications. With Manual Transmission 1. Disconnect battery ground cable, then raise and support vehicle. 2. Support transmission with transmission jack. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 891 Fig. 4 Rear Engine Mount. 2WD W/manual Transmission 3. Remove stud nuts attaching insulator to transmission extension, Fig.4. 4. Raise transmission and engine slightly and remove stud nuts attaching insulator to crossmember. 5. Remove engine mount. 6. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292, or equivalent. Start engine and record pressure. OIL PRESSURE: At Curb Idle .......................................................................................................................................... .................................................... 41.4 kPa (6 psi) At 3000 RPM ........................................................ .................................................................................................................. 207 - 552 kPa (30 - 80 psi) CAUTION: If oil pressure is zero at curb idle, do not run engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug 25 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil 2.5L Without Filter Change .................................................................................................................. ............................................................ 3.8L (4.0 Qt) 3.9L Without Filter Change ................................ .............................................................................................................................................. 3.3L (3.9 Qt) 5.2L, 5.9L Without Filter Change ................................................................................................... .................................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 903 Engine Oil: Fluid Type Specifications ENGINE OIL SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. - SAE 30 = single grade engine oil. - SAE 10W-30 = multiple grade engine oil. API QUALITY CLASSIFICATION The API Service Grade specifies the type of performance the engine oil is intended to provide. The API Service Grade specifications also apply to energy conserving engine oils. Use engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. MOPAR engine oils conform to all of these service grades. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair 1. Disconnect battery ground cable, then remove oil dipstick. 2. Disconnect distributor cap and set aside away from cowl, then raise and support vehicle. 3. Drain engine oil, then remove exhaust crossover pipe. 4. Loosen side engine mount bolts, then using suitable jack and wood block positioned at oil pan, raise engine slightly and remove side engine mount bolts. 5. When engine is high enough, place bolts similar to engine mount bolts in mount attaching points on frame brackets. Lower engine so mount bottoms rest on installed bolts. 6. Remove oil pan and gasket. 7. Reverse procedure to install. Apply in corner of cap and block. Tighten attaching bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. The gauge uses two coils. One coil receives fixed current. Circuit G60 connects the other coil to the pressure sensor. As oil pressure changes, the variable resistor in the sensor changes the current flow through the second coil in the gauge. A change in current flow alters the position of the gauge pointer. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Page 910 Oil Pressure Gauge: Testing and Inspection Actual engine oil pressure should be checked with a test gauge and compared with gauge readings prior to performing gauge diagnostic procedures. 1. Place ignition switch in On position, then disconnect sending unit connector and observe gauge. Needle should move to or remain at low end of scale. 2. Connect a jumper wire between cavity 1 of sending unit connector and ground and observe gauge. Needle should move to high end of scale. 3. If gauge performs as specified, replace sending unit; if not, proceed as follows: a. Remove jumper wire and place ignition switch in Off position, then disconnect battery ground cable and remove instrument cluster and bezel. b. Disconnect gray connector from righthand side of cluster, then probe connector cavity K for continuity to ground. If continuity exists, repair short as necessary; if not, continue with procedure. Fig. 5 Oil Pressure Sending Unit Connector Terminal Identification c. Check for continuity between cavity 1 of sending unit wire connector, and gray cluster connector cavity K. If continuity exists, replace oil pressure gauge; if not, repair open circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 914 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The Low Oil Pressure lamp will illuminate when the ignition key is turned to the On position. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. 1. Turn ignition key to On position. 2. If lamp fails to illuminate, check for the following conditions: a. A broken or disconnected wire at the oil pressure combination unit, located at rear of engine. b. If wire is satisfactory, pull connector loose from switch and connect a jumper wire from ground to engine. c. If lamp does not illuminate with ignition switch in On position, inspect for a faulty bulb or disconnected socket in the instrument cluster. 3. If lamp illuminates, start engine. If lamp remains on, immediately stop engine and check oil pressure with a test gauge. If oil pressure is satisfactory, check for a grounded wire and/or replace oil pressure sending unit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292, or equivalent. Start engine and record pressure. OIL PRESSURE: At Curb Idle .......................................................................................................................................... .................................................... 41.4 kPa (6 psi) At 3000 RPM ........................................................ .................................................................................................................. 207 - 552 kPa (30 - 80 psi) CAUTION: If oil pressure is zero at curb idle, do not run engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 927 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 928 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 929 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 930 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 931 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 937 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 938 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 939 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 940 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 941 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 942 Intake Manifold: Specifications Intake Manifold Bolts 12 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 943 Intake Manifold: Service and Repair REMOVAL 1. Disconnect battery ground cable, then drain cooling system. 2. Remove air cleaner and alternator. Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 3. Release fuel system pressure as follows: a. Remove the negative battery cable, and remove the fuel tank fill cap. b. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. c. Remove the cap from the pressure test port on the fuel rail. d. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. e. Install cap on test port. 4. Remove fuel lines and fuel rail. 5. Disconnect throttle linkage, speed control and transmission kickdown cables, then remove throttle return spring. 6. Remove distributor cap and wires, then disconnect coil wires. 7. Disconnect heat indicator sending unit wire, then remove heater and bypass hoses. 8. Remove closed crankcase ventilation and evaporation control systems. 9. Remove intake manifold bolts, then lift intake manifold and throttle body out of engine compartment. 10. Remove and discard flange side as well as front and rear crossover gaskets. 11. Remove throttle body and discard gasket. 12. Support upside down manifold, then remove plenum pan bolts and lift pan off manifold. Discard gaskets. INSTALLATION Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 944 1. Install plenum pan using a new gasket, hand tighten bolts. Fig. 9 Plenum Pan Bolt Tightening Sequence 2. Tighten bolts in sequence show in Fig.9. First, torque bolts to 24 inch lbs., then to 48 inch lbs., and finally, to 84 inch lbs. 3. Install throttle body with new gasket. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 945 Fig. 10 Intake Manifold Locator Dowels 4. Install four plastic locator dowels into block holes, Fig.10. 5. Apply silicone rubber adhesive sealant slightly higher than crossover gasket (approximately 0.2 inch) to four corner joints. Excessive sealant may reduce flange gasket effectiveness. 6. Install front and rear crossover gaskets onto dowels, then install flange gasket. Ensure vertical port alignment tab is resting on block deck face and horizontal tabs align with mating cylinder head gasket tabs. 7. Lower manifold into position and ensure seal placement, then remove alignment studs. Fig.11 Intake Manifold Tightening Sequence Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 946 8. Tighten intake manifold bolts in sequence shown in Fig.11. First, torque bolts 1 and 2 to 72 inch lbs. in alternating 12 inch lbs. steps, then torque bolts 3 through 12 to 72 inch lbs. Finally, torque all bolts to 12 ft. lbs. 9. Install closed crankcase ventilation and evaporation control systems. 10. Connect coil and heat indicator sending unit wires, then install heater and bypass hoses. 11. Install distributor cap and wires, then connect accelerator linkage, speed control and transmission kickdown cables. 12. Install fuel lines, fuel rail, alternator, serpentine belt and air cleaner. 13. Fill cooling system and connect battery ground cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. The gauge uses two coils. One coil receives fixed current. Circuit G60 connects the other coil to the pressure sensor. As oil pressure changes, the variable resistor in the sensor changes the current flow through the second coil in the gauge. A change in current flow alters the position of the gauge pointer. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Page 951 Oil Pressure Gauge: Testing and Inspection Actual engine oil pressure should be checked with a test gauge and compared with gauge readings prior to performing gauge diagnostic procedures. 1. Place ignition switch in On position, then disconnect sending unit connector and observe gauge. Needle should move to or remain at low end of scale. 2. Connect a jumper wire between cavity 1 of sending unit connector and ground and observe gauge. Needle should move to high end of scale. 3. If gauge performs as specified, replace sending unit; if not, proceed as follows: a. Remove jumper wire and place ignition switch in Off position, then disconnect battery ground cable and remove instrument cluster and bezel. b. Disconnect gray connector from righthand side of cluster, then probe connector cavity K for continuity to ground. If continuity exists, repair short as necessary; if not, continue with procedure. Fig. 5 Oil Pressure Sending Unit Connector Terminal Identification c. Check for continuity between cavity 1 of sending unit wire connector, and gray cluster connector cavity K. If continuity exists, replace oil pressure gauge; if not, repair open circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 955 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The Low Oil Pressure lamp will illuminate when the ignition key is turned to the On position. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. 1. Turn ignition key to On position. 2. If lamp fails to illuminate, check for the following conditions: a. A broken or disconnected wire at the oil pressure combination unit, located at rear of engine. b. If wire is satisfactory, pull connector loose from switch and connect a jumper wire from ground to engine. c. If lamp does not illuminate with ignition switch in On position, inspect for a faulty bulb or disconnected socket in the instrument cluster. 3. If lamp illuminates, start engine. If lamp remains on, immediately stop engine and check oil pressure with a test gauge. If oil pressure is satisfactory, check for a grounded wire and/or replace oil pressure sending unit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair 1. Remove oil pan, then the oil pump from rear main bearing cap. 2. Remove rear main bearing cap. 3. Carefully remove and discard upper and lower oil seals. 4. Clean cylinder block and rear main cap mating surfaces including oil pan gasket groove. Check cylinder block to rear cap oil hole for burr. 5. Lightly oil new seal lips with engine oil, then loosen at least two main bearing caps forward of rear bearing cap. 6. Install bearings with white paint facing rear of engine. 7. Use tool provided with kit, to ensure proper installation. Be careful not to cut or shave outer surface seal while rotating new upper seal into cylinder block. Place lower seal in bearing cap. Fig. 17 Location Of Bearing Cap Sealant 8. Apply 0.20 inch drop of Loctite 515 or equivalent to each side of rear main bearing cap, Fig.17. Ensure sealant does not contact rubber seal and do not over apply. Immediately assemble cap to block immediately after sealant application. 9. Align bearing cap using cap slot, alignment dowel and cap bolts. Do not strike rear cap more than twice for proper contact. Do not remove excess material after assembly. 10. Install cleaned and oiled cap bolts. Alternately tighten bolts to specifications. 11. Install oil pump. Fig. 18 Location Of Bearing Cap To Block Joint Sealant 12. Apply silicone rubber adhesive sealant at bearing cap to block joint, Fig.18. Apply sealant until a small amount is squeezed out. Wipe excess off oil pan seal groove and immediately install oil pan, then tighten pan bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair The front crankshaft oil seal can be replaced without removing timing chain cover if cover is not misaligned. 1. Disconnect battery ground cable, then remove vibration damper. 2. Pry oil seal out, being careful not to damage cover crankshaft seal surface. 3. Place smaller diameter oil seal over front oil seal installation tool No. 6635, or equivalent, and seat seal in tool groove. 4. Position seal and tool onto crankshaft and use vibration damper bolt to draw seal into position. 5. Remove damper bolt and tool, then inspect seal flange. 6. Install vibration damper and connect battery ground cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 971 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 972 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 973 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 974 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 975 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 981 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 982 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 983 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 984 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 985 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt 35 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair 1. Disconnecting battery ground cable, then drain cooling system. 2. Remove serpentine belt, water pump, power steering pump and vibration damper. Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 3. Release fuel system pressure as follows: a. Remove the negative battery cable, and remove the fuel tank fill cap. b. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. c. Remove the cap from the pressure test port on the fuel rail. d. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. e. Install cap on test port. 4. Loosen oil pan bolts and remove front bolt on each side, then remove time chain cover bolts. 5. Carefully remove timing chain cover and gasket to avoid damaging oil pan gasket. 6. Remove front crankshaft oil seal. 7. Place scale next to timing chain link to measure any movement. 8. Place a torque wrench and socket over camshaft sprocket attaching bolts and turn in crankshaft rotation direction to take up slack. It may be necessary to block crankshaft to prevent rotation. Apply torque of 30 ft. lbs. with cylinder head installed or 15 ft. lbs. with cylinder head removed. 9. Reverse rotation direction using same torques stated in previous step and measure chain movement. Install new timing chain if movement is more than 1/8 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 993 Fig. 15 Aligning Valve Timing Marks 10. If chain is not satisfactory, align timing marks as shown in Fig.15. 11. Remove camshaft sprocket bolts, then remove the timing chain with crankshaft and camshaft sprockets. 12. Reverse procedure to install. Ensure timing marks stay properly aligned. Tighten bolts to specifications. With a new thrust plate, camshaft endplay should be 0.002-0.006 inch. With a used thrust plate, camshaft endplay should be 0.006-0.010 inch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 999 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1002 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1003 5. Connect vehicle fuel line into adapter tool 6923. Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T". 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 9. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 1988 - 1996 3.9L (238) Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 1988 - 1996 3.9L (238) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1026 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1027 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1028 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1029 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1030 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1031 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1037 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1038 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1039 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1040 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1041 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1042 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1043 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1044 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1045 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Description and Operation Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1058 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1059 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1060 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1061 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1062 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Oil or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1063 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced, or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1064 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1065 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 0.89 mm (0.035 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum compression pressure should be 100 psi. Maximum variation between cylinders is 25 percent. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments These engines use hydraulic lifters. No provision for adjustment is provided. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal WATER PUMPS Water Pump Removal (1) Drain cooling system. If equipped with air-conditioning, remove radiator. (2) Loosen alternator adjusting strap bolt and pivot bolt. Loosen power steering and air pumps, if so equipped. Remove all drive belts. (3) On engines without air-conditioning remove alternator bracket attaching bolts from water pump. Swing alternator out of the way and tighten pivot bolt. (4) On engines with air-conditioning, remove alternator, adjusting bracket, and power steering pump attaching bolts and set aside. (5) Remove fan blade, spacer (or fluid unit), pulley and bolts as an assembly. CAUTION: To prevent silicone fluid from draining into fan drive bearing and ruining the lubricant, do not place drive unit with shaft pointing downward (if so equipped). (6) Disconnect heater and by-pass hoses. (7) Remove air-conditioning compressor pulley and field coil assembly. (8) Remove water pump-to-compressor front mount bracket bolts and bracket. (9) Remove pump retaining bolts and water pump assembly. Discard gasket and clean mating surfaces. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1077 Water Pump: Service and Repair Installation Water Pump Installation (1) Install a new by-pass hose, if necessary, with clamp positioned in the center of the hose. (2) Install water pump using a new gasket. Tighten engine pump retainer bolts to 30 ft. lbs. (41 N.m). Rotate pump by hand to be sure it rotates freely. (3) Install heater hose and position by-pass hose clamps. (4) On engines without air-conditioning, install alternator front bracket and tighten to 30 ft. lbs. (41 N.m). (5) On engines with air-conditioning, install compressor front bracket. Tighten compressor bracket bolts to 50 ft. lbs. (68 N.m) and water pump retainer bolts to 30 ft. lbs. (41 N.m). Install alternator, adjusting bracket and power steering pump. Tighten all bolts to 30 ft. lbs. (41 N.m). Install compressor clutch assembly. (6) Install fan, spacer (or fluid unit), pulley and bolts as an assembly. (7) Install belts and adjust tension as described in belt tightening procedures. (8) Connect heater hose. Install radiator as outlined in this section. (9) Fill cooling system. See "Refilling Cooling System". Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1083 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1084 Coolant: Specifications Engine ................................................................................................................................................. ............................................................... 3.9L/V6-238 Coolant Capacity Less A/C, Qts. ......................................................................................................... .................................................................................................... 14 [03] With A/C, Qts. ..................... .............................................................................................................................................................. ......................... 14 [03] Radiator Cap Relief Pressure, Lbs. ..................................................................................................... .......................................................................... 14-18 Thermo. Opening Temp., °F .......................... .............................................................................................................................................................. .... 192 Fuel Tank, Gals. ...................................................................................................................... ........................................................................................ [01] Engine Oil Refill, Qts. [04] ................... .............................................................................................................................................................. ................. 4 Transmission Oil 4 Speed, Pints ......................................................................................................... ............................................................................................................. -- 5 Speed, Pints [02] ............. .............................................................................................................................................................. ................................. 4.2 Auto. Trans., Qts. [02] ................................................................................. ..................................................................................................... 4.75-5.5 [05] [01] -- Standard fuel tank, 15 gals., Optional fuel tank, 22 gals. [02] -- Transfer case, 2.5 pints. [03] -- With 26 inch maximum cooling radiator, 14.3 quarts. [04] -- Includes oil filter. [05] -- Depending on type & size of internal cooler, length & diameter of cooler lines, or use of auxiliary cooler. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1085 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1090 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1091 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1092 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1093 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair REMOVAL 1. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Place the unit on a work bench and remove the housing top cover. 3. Remove the attaching screw from the heater core retaining bracket and lift the heater core from the housing. INSTALLATION 1. Position the heater core in the heater-A/C housing. 2. Install and tighten the attaching screw to the heater core retaining bracket. 3. Install the housing top cover. 4. Install the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION Circuit G20 connects the engine coolant temperature gauge to the engine coolant temperature sensor. The sensor is a variable resistor and case grounded to the engine. As current flows through the coils in the gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the temperature gauge on circuit G20. A change in temperature changes the resistance in the sensor, which alters the current flow through the second coil in the gauge. A change in current flow alters the magnetic field in the gauge, which changes the pointer position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1101 Temperature Gauge: Testing and Inspection Engine coolant temperature should be measured with a thermometer and compared to gauge reading prior to performing gauge diagnostic procedures. If it is determined that actual coolant temperature does not match gauge indication, proceed as follows: 1. Place ignition switch in On position, then disconnect coolant temperature sending unit connector and observe gauge; needle should drop to lowest position on scale. If gauge does not perform as specified, continue with procedure. If not, proceed as follows: a. Connect a suitable jumper wire between sending unit wiring and ground and observe gauge; needle should move to highest position on scale. b. If gauge performs as specified, replace sending unit; if not, continue with procedure. 2. Place ignition switch in Off position and disconnect battery ground cable, then remove instrument cluster and bezel. 3. Probe cavity J of printed circuit No. 1 connector to determine if there is continuity to a good ground source; no continuity should exist. If there is continuity, repair short in circuit as necessary. 4. Check for continuity between cavity J and sending unit wiring connector. If continuity exists, replace gauge; if not, repair open in circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair 1. Disconnect battery ground cable, then drain cooling system. 2. Remove throttle cable at fan shroud, then unsnap and remove overflow tank from shroud. 3. Remove two fan shroud retaining clips and move toward engine. Shroud does not have to be removed from vehicle. 4. Disconnect transmission cooler lines, then remove upper and lower radiator hose clamps and hoses. 5. Remove two upper radiator support bolts and lift radiator out of vehicle. 6. Reverse procedure to install. Insert two bottom alignment pins into holes in lower support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1110 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1111 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1112 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1113 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION Circuit G20 connects the engine coolant temperature gauge to the engine coolant temperature sensor. The sensor is a variable resistor and case grounded to the engine. As current flows through the coils in the gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the temperature gauge on circuit G20. A change in temperature changes the resistance in the sensor, which alters the current flow through the second coil in the gauge. A change in current flow alters the magnetic field in the gauge, which changes the pointer position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1117 Temperature Gauge: Testing and Inspection Engine coolant temperature should be measured with a thermometer and compared to gauge reading prior to performing gauge diagnostic procedures. If it is determined that actual coolant temperature does not match gauge indication, proceed as follows: 1. Place ignition switch in On position, then disconnect coolant temperature sending unit connector and observe gauge; needle should drop to lowest position on scale. If gauge does not perform as specified, continue with procedure. If not, proceed as follows: a. Connect a suitable jumper wire between sending unit wiring and ground and observe gauge; needle should move to highest position on scale. b. If gauge performs as specified, replace sending unit; if not, continue with procedure. 2. Place ignition switch in Off position and disconnect battery ground cable, then remove instrument cluster and bezel. 3. Probe cavity J of printed circuit No. 1 connector to determine if there is continuity to a good ground source; no continuity should exist. If there is continuity, repair short in circuit as necessary. 4. Check for continuity between cavity J and sending unit wiring connector. If continuity exists, replace gauge; if not, repair open in circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair 1. Disconnect battery ground cable, then drain coolant to below thermostat level. Fig. 22 Alternator Support Bracket 2. On models with A/C, remove alternator support bracket, then partially remove alternator for access to thermostat. 3. Remove upper radiator hose at thermostat housing. 4. Move wiring harness behind thermostat housing out of the way. 5. Remove thermostat housing bolts, then housing, thermostat and gasket. 6. Reverse procedure to install with housing FRONT stamp pointed toward vehicle front. Tighten all bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal WATER PUMPS Water Pump Removal (1) Drain cooling system. If equipped with air-conditioning, remove radiator. (2) Loosen alternator adjusting strap bolt and pivot bolt. Loosen power steering and air pumps, if so equipped. Remove all drive belts. (3) On engines without air-conditioning remove alternator bracket attaching bolts from water pump. Swing alternator out of the way and tighten pivot bolt. (4) On engines with air-conditioning, remove alternator, adjusting bracket, and power steering pump attaching bolts and set aside. (5) Remove fan blade, spacer (or fluid unit), pulley and bolts as an assembly. CAUTION: To prevent silicone fluid from draining into fan drive bearing and ruining the lubricant, do not place drive unit with shaft pointing downward (if so equipped). (6) Disconnect heater and by-pass hoses. (7) Remove air-conditioning compressor pulley and field coil assembly. (8) Remove water pump-to-compressor front mount bracket bolts and bracket. (9) Remove pump retaining bolts and water pump assembly. Discard gasket and clean mating surfaces. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1126 Water Pump: Service and Repair Installation Water Pump Installation (1) Install a new by-pass hose, if necessary, with clamp positioned in the center of the hose. (2) Install water pump using a new gasket. Tighten engine pump retainer bolts to 30 ft. lbs. (41 N.m). Rotate pump by hand to be sure it rotates freely. (3) Install heater hose and position by-pass hose clamps. (4) On engines without air-conditioning, install alternator front bracket and tighten to 30 ft. lbs. (41 N.m). (5) On engines with air-conditioning, install compressor front bracket. Tighten compressor bracket bolts to 50 ft. lbs. (68 N.m) and water pump retainer bolts to 30 ft. lbs. (41 N.m). Install alternator, adjusting bracket and power steering pump. Tighten all bolts to 30 ft. lbs. (41 N.m). Install compressor clutch assembly. (6) Install fan, spacer (or fluid unit), pulley and bolts as an assembly. (7) Install belts and adjust tension as described in belt tightening procedures. (8) Connect heater hose. Install radiator as outlined in this section. (9) Fill cooling system. See "Refilling Cooling System". Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation DESCRIPTION There is no regularly scheduled maintenance on any Mopar stainless steel catalytic converter body. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. CAUTION: Unleaded gasoline must be used in gas engines to avoid contaminating the catalyst core. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1131 Catalytic Converter: Service and Repair Fig. 3 Exhaust Pipe - Light Duty REMOVAL 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove clamps and nuts. 4. Disconnect the catalytic converter from the support hanger. 5. Remove the catalytic converter. INSTALLATION 1. Connect the support hanger. 2. Assemble converter and clamps loosely to permit proper clearance with exhaust heat shields and underbody parts. 3. Tighten all clamp nuts to 43 N.m (32 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Nuts 25 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1135 Exhaust Manifold: Service and Repair 1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove bolts and nuts attaching exhaust pipe to exhaust manifold. 3. Lower vehicle, then remove exhaust manifold bolts, nuts and washers, and exhaust manifold. 4. Reverse procedure to install, noting the following: a. Install exhaust manifold on two cylinder head studs using conical washers and nuts. b. Install new bolts and washers in remaining holes. c. Starting from center, working outward, tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check Powertrain Control Module: Technical Service Bulletins PCM - Cruise Control System Check NO: 08-01-96 GROUP: Electrical DATE: Jan. 19, 1996 SUBJECT: Speed Control Light Flickers and/or Servo Clicks MODELS: 1996 (BR) Ram Truck 1996 (AN) Dakota 1996 (AB) Ram Van/wagon 1996 (XJ) Cherokee SYMPTOM/CONDITION: The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo when the ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF. DISCUSSION: The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignition key to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speed control indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servo receives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systems check when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have any adverse effects on the electrical system within the vehicle. Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normal operation of the system. NOTE: Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1143 Powertrain Control Module: Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1144 Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1145 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1146 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1147 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1148 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1149 Powertrain Control Module: Locations Powertrain Control Module The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment, mounted to the inner fender. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture Powertrain Control Module: Description and Operation Architecture Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1171 Powertrain Control Module: Description and Operation Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1172 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: - engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1173 In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1174 Powertrain Control Module: Description and Operation Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1175 Powertrain Control Module: Description and Operation Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1176 Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1177 Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. On-Board Diagnostics ON BOARD DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called "on-board diagnosis." Certain criteria, or "arming conditions," must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1178 Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring - Misfire Detection - EGR System Monitor - Oxygen Sensor Upstream Heater Monitor - Oxygen Sensor Upstream Monitor - Evaporative System Monitor - Catalyst Monitor - Purge Flow Monitor - 02 Heater Downstream Monitor - 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the "Catalyst Monitor" test will not be run unless the "O2 Sensor" test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS - Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: Idle Air Control (IAC) Open/Short Circuit - Generator Field - Torque Converter Clutch (TCC) Solenoid - Fan Relay - A/C Relay - Air Switch / Shift Lock Solenoid - Transmission Relay Output - Automatic Shutdown (ASD) Relay - Fuel Pump Relay - EVAP Purge Solenoid - EGR Solenoid - Ignition Coils - Injector Failure Z2 CIRCUIT CHECKS - Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) - Intake Air Temperature (IAT) Sensor Voltage (high/low) - Engine Coolant Temperature (ECT) Sensor Voltage (high/low) - Throttle Position Sensor (TPS) Voltage (high/low) - Manifold Absolute Pressure (MAP) Sensor 5 Volt Supply Check - Compressed Natural Gas (CNG) Pressure Sensor Voltage (high/low) - CNG Temperature Sensor Voltage (high/low) - Battery Temperature Sensor Voltage (high/low) - Fuel Level Sensor Voltage (high/low) - Transmission Temperature Sensor Voltage (high/low) - Governor Pressure Sensor Voltage (high/low) - Governor Pressure Solenoid (open/short) - ASD Relay Voltage (out of range) - Battery Voltage (too high) - Overdrive Override Switch (fault) - Leak Detection Pump Solenoid (open/short) - 3/4 Shift Solenoid (open/short) - Speed Control Vacuum and Vent Solenoids (open/short) FUNCTIONALITY/RATIONALITY CHECKS - These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present - Crank Sensor Pulses Present - MAP Sensor Output in Range Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1179 - Coolant Temperature in Range - Throttle Position Sensor in Range - Vehicle Speed Sensor Output Correct - Park/Neutral Switch Working - Fuel Level Sensor Output Correct - Transmission Temperature Sensor Output Correct - Transmission Governor Pressure in Range - Output Shaft Speed Sensor Output Correct - AIS Motor Working - Lock-up Solenoid Working - 3/4 Shift Solenoid Working - Governor Pressure Solenoid Working - O2 Sensor 1/1 Output Voltage Low - O2 Sensor 1/2 Output Voltage Low - O2 Sensor 2/1 Output Voltage Low - O2 Sensor 2/2 Output Voltage Low - Charging System Working - Power Steering Switch Working - Thermostat Working - O2 Sensor 1/1 (open circuit or high voltage) - O2 Sensor 1/2 (open circuit or high voltage) - O2 Sensor 2/1 (open circuit or high voltage) - O2 Sensor 2/2 (open circuit or high voltage) Cruise Control CRUISE CONTROL The Powertrain Control Module (PCM) controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation EXHAUST GAS RECIRCULATION The Powertrain Control Module (PCM) controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System FUEL VAPOR RECOVERY SYSTEM (DUTY CYCLE PURGE CONTROL) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the Powertrain Control Module (PCM). The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 Hz signal (at closed throttle) or 10 Hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulse width and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum. Overview OVERVIEW The Powertrain Control Module (PCM) features a multi-processor environment (one 16 bit microcomputer, two 8 bit micro-computers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of up to a ten cylinder engine running in excess of 6,500 RPM. Spark Control SPARK CONTROL The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed. Transmission Control Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1180 TRANSMISSION CONTROL The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling. Sump Pump Temperature Sensing A thermistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 1181 Powertrain Control Module: Service and Repair PCM Location REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1185 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1186 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1187 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1195 Except CNG Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1196 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the fuel pump relay. The Powertrain Control Module (PCM) energizes the relay by providing ground for the relay coil on circuit K31. Circuit K31 connects to cavity C19 of the PCM. When the PCM energizes the relay, the contacts close and connect circuit A14 from fuse D in the PDC to circuit A141. Circuit A141 powers the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1197 Fuel Pump Relay: Testing and Inspection Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. Circuit A21 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1201 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1202 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1203 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1209 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1210 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1214 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1217 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1218 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1219 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1223 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1224 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1225 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1226 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1230 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1233 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 1236 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1237 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation CIRCUIT OPERATION The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit G8 from the level sensor connects to cavity C26 of the Powertrain Control Module (PCM). Circuit G8 provides the fuel level input to the PCM. Circuit K4 provides ground for the signal. Circuit Z1 provides the ground path for the fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1244 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1245 Intake Air Temperature Sensor: Description and Operation CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig. 68 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. NOTE: for additional testing information, see Testing and Inspection/Test TC-57A or Test TC-58A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 1248 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 1249 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Remove air cleaner assembly. Fig. 68 Intake Manifold Air Temperature Sensor 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1253 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1254 Manifold Pressure/Vacuum Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1255 Manifold Pressure/Vacuum Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1256 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 86 MAP Sensor L-Shaped Rubber Fitting The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1261 Oxygen Sensor: Locations Oxygen Sensor(s) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views Oxygen Sensor: Connector Views Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views > Page 1264 JTEC O2 Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1265 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information - Along with supplying voltage to the ASD relay contacts, circuit A14 supplies voltage to the contact side of the fuel pump relay. - Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1268 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter (Fig. 62). Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 1269 Oxygen Sensor: Service and Repair Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1276 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1277 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1278 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1279 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1283 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1306 Vehicle Speed Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuits T33 and K7. Circuit T33 connects to circuit K7. Circuit T33 connects to cavity B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1307 Vehicle Speed Sensor: Testing and Inspection Circuit G7 splices to the speedometer and Daytime Running Lamps (DRL) module. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1308 Vehicle Speed Sensor: Service and Repair Fig. 18 Vehicle Speed Sensor Location - 2WD REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt. Fig. 105 Sensor Removal/Installation 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter. Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 N.m (20 in. lbs.) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1313 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1314 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1315 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1316 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1321 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1324 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1325 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1326 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1330 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1333 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 1336 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1337 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1341 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1342 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1343 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 1344 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1350 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1353 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1354 5. Connect vehicle fuel line into adapter tool 6923. Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T". 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 9. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 1988 - 1996 3.9L (238) Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 1988 - 1996 3.9L (238) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1377 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1378 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1379 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1380 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1381 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1382 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1388 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1389 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1390 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1391 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1392 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1393 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1394 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1395 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1396 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Description and Operation Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1409 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1410 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1411 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1412 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1413 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Oil or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1414 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced, or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1415 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1416 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 0.89 mm (0.035 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum compression pressure should be 100 psi. Maximum variation between cylinders is 25 percent. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments These engines use hydraulic lifters. No provision for adjustment is provided. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations > Page 1427 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1431 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1432 Intake Air Temperature Sensor: Description and Operation CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig. 68 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. NOTE: for additional testing information, see Testing and Inspection/Test TC-57A or Test TC-58A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 1435 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 1436 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Remove air cleaner assembly. Fig. 68 Intake Manifold Air Temperature Sensor 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1440 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1441 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation Brake Signal: Description and Operation PURPOSE Allows Engine Controller to monitor brake application. OPERATION The switch, mounted on brake pedal support bracket, closes when pedal is depressed. The engine controller uses switch input to determine engine load and maintain idle speed. The engine controller vents speed control system vacuum and turns speed control system OFF when brake switch actuation is sensed. The brake switch is also used as an input to signal deceleration. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1448 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1451 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1452 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1453 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1457 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1458 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1459 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1460 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1464 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1467 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 1470 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1471 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 1475 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 1476 Data Link Connector: Testing and Inspection - The grounding point for circuit Z12 is the rear of the engine. - Circuit Z12 also supplies a ground for the PCM high current drivers. - If the system loses ground for the Z12 circuits at the rear of the engine, the vehicle will not operate. Check the connection at the ganged-ground circuit eyelet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check Powertrain Control Module: Technical Service Bulletins PCM - Cruise Control System Check NO: 08-01-96 GROUP: Electrical DATE: Jan. 19, 1996 SUBJECT: Speed Control Light Flickers and/or Servo Clicks MODELS: 1996 (BR) Ram Truck 1996 (AN) Dakota 1996 (AB) Ram Van/wagon 1996 (XJ) Cherokee SYMPTOM/CONDITION: The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo when the ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF. DISCUSSION: The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignition key to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speed control indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servo receives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systems check when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have any adverse effects on the electrical system within the vehicle. Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normal operation of the system. NOTE: Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1481 Powertrain Control Module: Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1482 Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1483 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1484 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1485 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1486 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1487 Powertrain Control Module: Locations Powertrain Control Module The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment, mounted to the inner fender. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture Powertrain Control Module: Description and Operation Architecture Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1509 Powertrain Control Module: Description and Operation Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1510 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1511 In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1512 Powertrain Control Module: Description and Operation Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1513 Powertrain Control Module: Description and Operation Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1514 Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1515 Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. On-Board Diagnostics ON BOARD DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called "on-board diagnosis." Certain criteria, or "arming conditions," must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1516 Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring - Misfire Detection - EGR System Monitor - Oxygen Sensor Upstream Heater Monitor - Oxygen Sensor Upstream Monitor - Evaporative System Monitor - Catalyst Monitor - Purge Flow Monitor - 02 Heater Downstream Monitor - 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the "Catalyst Monitor" test will not be run unless the "O2 Sensor" test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS - Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: Idle Air Control (IAC) Open/Short Circuit - Generator Field - Torque Converter Clutch (TCC) Solenoid - Fan Relay - A/C Relay - Air Switch / Shift Lock Solenoid - Transmission Relay Output - Automatic Shutdown (ASD) Relay - Fuel Pump Relay - EVAP Purge Solenoid - EGR Solenoid - Ignition Coils - Injector Failure Z2 CIRCUIT CHECKS - Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) - Intake Air Temperature (IAT) Sensor Voltage (high/low) - Engine Coolant Temperature (ECT) Sensor Voltage (high/low) - Throttle Position Sensor (TPS) Voltage (high/low) - Manifold Absolute Pressure (MAP) Sensor 5 Volt Supply Check - Compressed Natural Gas (CNG) Pressure Sensor Voltage (high/low) - CNG Temperature Sensor Voltage (high/low) - Battery Temperature Sensor Voltage (high/low) - Fuel Level Sensor Voltage (high/low) - Transmission Temperature Sensor Voltage (high/low) - Governor Pressure Sensor Voltage (high/low) - Governor Pressure Solenoid (open/short) - ASD Relay Voltage (out of range) - Battery Voltage (too high) - Overdrive Override Switch (fault) - Leak Detection Pump Solenoid (open/short) - 3/4 Shift Solenoid (open/short) - Speed Control Vacuum and Vent Solenoids (open/short) FUNCTIONALITY/RATIONALITY CHECKS - These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present - Crank Sensor Pulses Present - MAP Sensor Output in Range Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1517 - Coolant Temperature in Range - Throttle Position Sensor in Range - Vehicle Speed Sensor Output Correct - Park/Neutral Switch Working - Fuel Level Sensor Output Correct - Transmission Temperature Sensor Output Correct - Transmission Governor Pressure in Range - Output Shaft Speed Sensor Output Correct - AIS Motor Working - Lock-up Solenoid Working - 3/4 Shift Solenoid Working - Governor Pressure Solenoid Working - O2 Sensor 1/1 Output Voltage Low - O2 Sensor 1/2 Output Voltage Low - O2 Sensor 2/1 Output Voltage Low - O2 Sensor 2/2 Output Voltage Low - Charging System Working - Power Steering Switch Working - Thermostat Working - O2 Sensor 1/1 (open circuit or high voltage) - O2 Sensor 1/2 (open circuit or high voltage) - O2 Sensor 2/1 (open circuit or high voltage) - O2 Sensor 2/2 (open circuit or high voltage) Cruise Control CRUISE CONTROL The Powertrain Control Module (PCM) controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation EXHAUST GAS RECIRCULATION The Powertrain Control Module (PCM) controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System FUEL VAPOR RECOVERY SYSTEM (DUTY CYCLE PURGE CONTROL) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the Powertrain Control Module (PCM). The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 Hz signal (at closed throttle) or 10 Hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulse width and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum. Overview OVERVIEW The Powertrain Control Module (PCM) features a multi-processor environment (one 16 bit microcomputer, two 8 bit micro-computers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of up to a ten cylinder engine running in excess of 6,500 RPM. Spark Control SPARK CONTROL The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed. Transmission Control Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1518 TRANSMISSION CONTROL The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling. Sump Pump Temperature Sensing A thermistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 1519 Powertrain Control Module: Service and Repair PCM Location REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation CIRCUIT OPERATION The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit G8 from the level sensor connects to cavity C26 of the Powertrain Control Module (PCM). Circuit G8 provides the fuel level input to the PCM. Circuit K4 provides ground for the signal. Circuit Z1 provides the ground path for the fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1526 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1527 Idle Speed/Throttle Actuator - Electronic: Description and Operation The Powertrain Control Module (PCM) operates the Idle Air Control motor through four circuits; K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. - Circuit K39 connects to cavity A19 of the PCM connector. - Circuit K4O connects to cavity A11 of the PCM connector. - Circuit K59 connects to cavity A20 of the PCM connector. - Circuit K60 connects to cavity A10 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1528 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1529 Idle Speed/Throttle Actuator - Electronic: Adjustments Fig. 33 Throttle Body And Sensor Locations A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1533 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1534 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1535 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation OPERATION The Powertrain Control Module (PCM) performs an on-board Diagnostic (OBD) check of the EGR system on all California vehicles. The diagnostic system uses the electronic EGR Transducer (EET) for the system tests. The OBD check activates only during selected engine/driving conditions. When the conditions are met, the PCM energizes the EET solenoid to disable the EGR. the PCM checks for a change in the oxygen sensor signal. If the air/fuel mixture goes lean, the PCM will attempt to enrich the mixture. The PCM registers a Diagnostic Trouble Code (DTC) if the EGR system has failed or degraded. After registering a DTC, the PCM turns the Malfunction Indicator Lamp (MIL) ON. The MIL indicates the need for immediate service. If a malfunction is indicated by the MIL and a DTC for the EGR system was set, check for proper operation of the EGR system. If the EGR system tests properly, check the system using the DRB II scan tool. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1542 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1543 Manifold Pressure/Vacuum Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1544 Manifold Pressure/Vacuum Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1545 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 86 MAP Sensor L-Shaped Rubber Fitting The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1550 Oxygen Sensor: Locations Oxygen Sensor(s) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views Oxygen Sensor: Connector Views Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views > Page 1553 JTEC O2 Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1554 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information - Along with supplying voltage to the ASD relay contacts, circuit A14 supplies voltage to the contact side of the fuel pump relay. - Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1557 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter (Fig. 62). Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 1558 Oxygen Sensor: Service and Repair Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check Powertrain Control Module: Technical Service Bulletins PCM - Cruise Control System Check NO: 08-01-96 GROUP: Electrical DATE: Jan. 19, 1996 SUBJECT: Speed Control Light Flickers and/or Servo Clicks MODELS: 1996 (BR) Ram Truck 1996 (AN) Dakota 1996 (AB) Ram Van/wagon 1996 (XJ) Cherokee SYMPTOM/CONDITION: The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo when the ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF. DISCUSSION: The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignition key to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speed control indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servo receives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systems check when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have any adverse effects on the electrical system within the vehicle. Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normal operation of the system. NOTE: Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1567 Powertrain Control Module: Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1568 Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1569 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1570 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1571 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > PCM - Cruise Control System Check > Page 1572 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1573 Powertrain Control Module: Locations Powertrain Control Module The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment, mounted to the inner fender. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture Powertrain Control Module: Description and Operation Architecture Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1595 Powertrain Control Module: Description and Operation Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1596 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: - engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1597 In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1598 Powertrain Control Module: Description and Operation Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1599 Powertrain Control Module: Description and Operation Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1600 Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1601 Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. On-Board Diagnostics ON BOARD DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called "on-board diagnosis." Certain criteria, or "arming conditions," must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1602 Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring - Misfire Detection - EGR System Monitor - Oxygen Sensor Upstream Heater Monitor - Oxygen Sensor Upstream Monitor - Evaporative System Monitor - Catalyst Monitor - Purge Flow Monitor - 02 Heater Downstream Monitor - 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the "Catalyst Monitor" test will not be run unless the "O2 Sensor" test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS - Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: Idle Air Control (IAC) Open/Short Circuit - Generator Field - Torque Converter Clutch (TCC) Solenoid - Fan Relay - A/C Relay - Air Switch / Shift Lock Solenoid - Transmission Relay Output - Automatic Shutdown (ASD) Relay - Fuel Pump Relay - EVAP Purge Solenoid - EGR Solenoid - Ignition Coils - Injector Failure Z2 CIRCUIT CHECKS - Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) - Intake Air Temperature (IAT) Sensor Voltage (high/low) - Engine Coolant Temperature (ECT) Sensor Voltage (high/low) - Throttle Position Sensor (TPS) Voltage (high/low) - Manifold Absolute Pressure (MAP) Sensor 5 Volt Supply Check - Compressed Natural Gas (CNG) Pressure Sensor Voltage (high/low) - CNG Temperature Sensor Voltage (high/low) - Battery Temperature Sensor Voltage (high/low) - Fuel Level Sensor Voltage (high/low) - Transmission Temperature Sensor Voltage (high/low) - Governor Pressure Sensor Voltage (high/low) - Governor Pressure Solenoid (open/short) - ASD Relay Voltage (out of range) - Battery Voltage (too high) - Overdrive Override Switch (fault) - Leak Detection Pump Solenoid (open/short) - 3/4 Shift Solenoid (open/short) - Speed Control Vacuum and Vent Solenoids (open/short) FUNCTIONALITY/RATIONALITY CHECKS - These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present - Crank Sensor Pulses Present - MAP Sensor Output in Range Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1603 - Coolant Temperature in Range - Throttle Position Sensor in Range - Vehicle Speed Sensor Output Correct - Park/Neutral Switch Working - Fuel Level Sensor Output Correct - Transmission Temperature Sensor Output Correct - Transmission Governor Pressure in Range - Output Shaft Speed Sensor Output Correct - AIS Motor Working - Lock-up Solenoid Working - 3/4 Shift Solenoid Working - Governor Pressure Solenoid Working - O2 Sensor 1/1 Output Voltage Low - O2 Sensor 1/2 Output Voltage Low - O2 Sensor 2/1 Output Voltage Low - O2 Sensor 2/2 Output Voltage Low - Charging System Working - Power Steering Switch Working - Thermostat Working - O2 Sensor 1/1 (open circuit or high voltage) - O2 Sensor 1/2 (open circuit or high voltage) - O2 Sensor 2/1 (open circuit or high voltage) - O2 Sensor 2/2 (open circuit or high voltage) Cruise Control CRUISE CONTROL The Powertrain Control Module (PCM) controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation EXHAUST GAS RECIRCULATION The Powertrain Control Module (PCM) controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System FUEL VAPOR RECOVERY SYSTEM (DUTY CYCLE PURGE CONTROL) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the Powertrain Control Module (PCM). The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 Hz signal (at closed throttle) or 10 Hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulse width and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum. Overview OVERVIEW The Powertrain Control Module (PCM) features a multi-processor environment (one 16 bit microcomputer, two 8 bit micro-computers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of up to a ten cylinder engine running in excess of 6,500 RPM. Spark Control SPARK CONTROL The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed. Transmission Control Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Architecture > Page 1604 TRANSMISSION CONTROL The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling. Sump Pump Temperature Sensing A thermistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 1605 Powertrain Control Module: Service and Repair PCM Location REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1609 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1610 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1611 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1616 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1617 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1621 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1624 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1625 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1626 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1630 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1631 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the powertrain control module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1632 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1633 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1637 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1640 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 1643 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1644 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation CIRCUIT OPERATION The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit G8 from the level sensor connects to cavity C26 of the Powertrain Control Module (PCM). Circuit G8 provides the fuel level input to the PCM. Circuit K4 provides ground for the signal. Circuit Z1 provides the ground path for the fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1651 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1652 Intake Air Temperature Sensor: Description and Operation CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig. 68 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the Coolant Temperature sensor/Intake Air Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector A-15 and the sensor connector terminal. Also check between PCM connector A-4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. NOTE: for additional testing information, see Testing and Inspection/Test TC-57A or Test TC-58A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 1655 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 1656 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Remove air cleaner assembly. Fig. 68 Intake Manifold Air Temperature Sensor 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1660 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1661 Manifold Pressure/Vacuum Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1662 Manifold Pressure/Vacuum Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1663 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 86 MAP Sensor L-Shaped Rubber Fitting The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1668 Oxygen Sensor: Locations Oxygen Sensor(s) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views Oxygen Sensor: Connector Views Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Connector Views > Page 1671 JTEC O2 Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1672 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information - Along with supplying voltage to the ASD relay contacts, circuit A14 supplies voltage to the contact side of the fuel pump relay. - Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1675 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter (Fig. 62). Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 1676 Oxygen Sensor: Service and Repair Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1683 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1684 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1685 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1686 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1690 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1713 Vehicle Speed Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuits T33 and K7. Circuit T33 connects to circuit K7. Circuit T33 connects to cavity B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1714 Vehicle Speed Sensor: Testing and Inspection Circuit G7 splices to the speedometer and Daytime Running Lamps (DRL) module. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1715 Vehicle Speed Sensor: Service and Repair Fig. 18 Vehicle Speed Sensor Location - 2WD REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt. Fig. 105 Sensor Removal/Installation 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter. Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 N.m (20 in. lbs.) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Shift Light > Component Information > Description and Operation Shift Light: Description and Operation CIRCUIT OPERATION The manual transmission up-shift lamp illuminates when the Powertrain Control Module (PCM) provides ground for the lamp on circuit K54. Circuit K54 connects to cavity B11 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1722 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1723 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1724 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1725 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1729 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1752 Vehicle Speed Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuits T33 and K7. Circuit T33 connects to circuit K7. Circuit T33 connects to cavity B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1753 Vehicle Speed Sensor: Testing and Inspection Circuit G7 splices to the speedometer and Daytime Running Lamps (DRL) module. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1754 Vehicle Speed Sensor: Service and Repair Fig. 18 Vehicle Speed Sensor Location - 2WD REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt. Fig. 105 Sensor Removal/Installation 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter. Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 N.m (20 in. lbs.) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation PURPOSE The engine controller continuously monitors battery voltage inputs, and since battery voltage always fluctuates, the engine controller will constantly be making changes to the injector pulse width and alternator field. OPERATION The engine controller monitors battery voltage to determine the proper injector pulse width and to control the alternator field voltage. If the engine controller sees low battery voltage, it will increase the injector pulse width to compensate for lack of voltage which could cause a lean air/fuel mixture. A higher voltage signal will be sent to the alternator field so that the alternator will increase its charging output to the battery. When the alternator increases its charging rate it will bring the battery up to its normal state of charge. Once the battery is fully charged, the engine controller reduces the injector pulse width so that the air/fuel mixture doesn't go excessively rich. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation DESCRIPTION There is no regularly scheduled maintenance on any Mopar stainless steel catalytic converter body. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. CAUTION: Unleaded gasoline must be used in gas engines to avoid contaminating the catalyst core. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 1762 Catalytic Converter: Service and Repair Fig. 3 Exhaust Pipe - Light Duty REMOVAL 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove clamps and nuts. 4. Disconnect the catalytic converter from the support hanger. 5. Remove the catalytic converter. INSTALLATION 1. Connect the support hanger. 2. Assemble converter and clamps loosely to permit proper clearance with exhaust heat shields and underbody parts. 3. Tighten all clamp nuts to 43 N.m (32 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Fig. 1 SRI Lamp Location The lamp is displayed on the instrument panel as the MAINT REQ'D lamp Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Locations > Page 1766 Emissions Maintenance Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 1771 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid Canister Purge Solenoid: Description and Operation Duty Cycle EVAP/Purge Solenoid Fig. 2 EVAP Purge Solenoid DESCRIPTION All engines use a duty cycle EVAP canister purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The Powertrain Control Module (PCM) operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM deenergizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid > Page 1774 Canister Purge Solenoid: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the EVAP/Purge solenoid by providing a ground path on circuit K52. Circuit K52 connects to PCM cavity C20. Circuit A21 supplies battery voltage to the EVAP/Purge solenoid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Page 1775 Canister Purge Solenoid: Testing and Inspection In the RUN or START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Page 1776 Canister Purge Solenoid: Service and Repair REMOVAL 1. Remove air cleaner housing. Fig. 88 EVAP Canister Purge Solenoid - Typical 2. Disconnect wiring connector at solenoid. 3. Disconnect vacuum harness at solenoid. 4. Remove solenoid and its support bracket from intake manifold. 5. Remove EVAP canister purge solenoid from engine. INSTALLATION 1. Install EVAP canister purge solenoid and its mounting bracket to intake manifold. 2. Connect vacuum harness and wiring connector. 3. Install air cleaner housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations EVAP Canister Location The canister is mounted inside the right fender. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 1780 Evaporative Emission Control Canister: Description and Operation Fig. 1 EVAP Canister PURPOSE The charcoal canister contains activated charcoal granules which absorb and store fuel vapors until they can be consumed during combustion. OPERATION The fuel resistant nylon body of the canister contains activated charcoal granules which absorb and store fuel vapors until they are drawn into the induction system to be burned along with the normal air/fuel mixture. During engine operation outside air is drawn into the canister through a filter pad located at the bottom of the canister. The stored vapors are drawn out of the canister into the incoming airstream where they are consumed during combustion. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair Crankcase Filter: Service and Repair CRANKCASE INLET AIR (BREATHER) FILTER Crankcase Inlet Air (Breather) Filter The crankcase inlet air (breather) cleaner must be kept clean and lubricated. At the recommended interval, remove the filter and wash it thoroughly in kerosene, or similar solvent. Lubricate or wet the filter by inverting the filter and filling with SAE 30 engine oil. Filter must then be thoroughly drained. More frequent service may be necessary for vehicles operated extensively on short run, stop and go, or extended engine idle service. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 1790 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1793 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1794 5. Connect vehicle fuel line into adapter tool 6923. Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T". 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 9. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 1805 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Filler Cap Pressure Vent Limit ........................................................................................................................................... 6.58 - 8.44 kPa (1.95 - 2.5 psi) Filler Cap Vacuum Vent Limit ............................................................................................................................................ 0.97 - 2.0 kPa (0.14 - 0.29 psi) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 1809 Fuel Filler Cap: Description and Operation Pressure-Vacuum Filler Cap PURPOSE The fuel filler cap is used to relieve excess fuel tank pressure or vacuum and prevents loss of any fuel or vapor out of the filler neck. OPERATION Relief valves inside cap will release only under significant pressure of 6.58 to 8.44 kPa (1.95 to 2.5 psi). The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). NOTE: This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. NOTE: It is normal to encounter an air pressure release when removing the fuel filler cap. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Regulator Location Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations Gas Engine Components Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 1817 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Circuit Information Fuel Injector: Description and Operation Circuit Information CIRCUIT OPERATION When the Automatic Shut Down (ASD) relay contacts close, they connect circuits A14 and A142. Circuit A142 supplies voltage to the fuel injectors. Each injector has a separate ground circuit controlled by the Powertrain Control Module (PCM). Circuit K11 provides ground for injector number one. The K11 circuit connects to cavity B4 of the PCM. Circuit K12 provides ground for injector number two. The K12 circuit connects to cavity B15 of the PCM. Circuit K13 provides ground for injector number three. The K13 circuit connects to cavity B5 of the PCM. Circuit K14 provides ground for injector number four. The K14 circuit connects to cavity B16 of the PCM. Circuit K26 provides ground for injector number seven. The K26 circuit connects to cavity B2 of the PCM. Circuit K28 provides ground for injector number eight. The K28 circuit connects to cavity B13 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Circuit Information > Page 1820 Fuel Injector: Description and Operation Fuel Injector Fig. 4 Fuel Injectors - Typical DESCRIPTION The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. OPERATION The injectors are energized individually in a sequential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 1821 Fuel Injector: Testing and Inspection Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 1822 Fuel Injector: Service and Repair Fuel Injector Location Fuel Injectors Fuel Injector Removal And Replacement NOTE: Fuel system pressure must be released prior to any service of fuel injection components. See: Fuel Filter/Fuel Pressure Release/Service and Repair REMOVAL 1. Disconnect the negative battery cable, and remove the fuel tank filler cap. 3. Remove the fuel rail from the intake manifold. See Fuel Delivery and Air Induction/Fuel Rail/Service and Repair. See: Fuel Rail/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 1823 4. Using a rocking motion, separate the fuel injectors and fuel rail from the intake manifold and discard all the old "O" rings. 5. Remove the fuel injectors from the fuel rail and discard all the old "O" rings. INSTALLATION 1. Install new O-ring seals on the top of each injector, before installation lightly lube each O-ring with clean motor oil. 2. Install each injector into its position on the fuel rail, and install the retainer clips. 3. Install a new O-ring onto the exposed end of each fuel injector, lightly lube each O-ring with clean motor oil. 4. Install the fuel injectors and fuel rail into the intake manifold and tighten fuel rail mounting bolts to 20 ft-lbs (27 Nm). 5. Reassemble Intake Manifold & Throttle Body as described in Fuel Rail/Service and Repair. 6. Connect the negative battery cable, and Install the fuel tank filler cap. 7. Connect the DRB II scan tool and select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. CAUTION: The interior components (0-rings, spacers) of quick-connect fitting are not serviced separately, but new pull tabs are available for some types. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type Fuel Line Coupler: Service and Repair Plastic Retainer Type Fig. 15 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To release the fuel system component from the quick-connect fitting, firmly push the fitting towards the component being serviced while firmly pushing the plastic retainer ring into the fitting. With the plastic ring depressed, pull the fitting from the component. The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of the plastic retainer ring to aid in disconnection. 5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery 11. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1829 Fuel Line Coupler: Service and Repair Fuel Line at Fuel Rail With Pressure Test Port Fig. 16 Latch Clip Location - Typical A latch clip is used to secure the fuel line to the fuel rail on certain engines. A special tool will be necessary to separate the fuel line from the fuel rail after the latch clip is removed. DISCONNECTION/CONNECTION AT FUEL RAIL 1. Disconnect the negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly Fig. 17 Latch Clip Removal - Typical 4. Pry up on the latch clip with a screwdriver. 5. Slide the latch clip toward the fuel rail while lifting with the screwdriver. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1830 Fig. 18 Fuel Line Disconnection - Typical 6. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into the fuel line. Use this tool to release the locking fingers in the end of the line. 7. With the special tool still inserted, pull the fuel line from the fuel rail. 8. After disconnection, the locking fingers will remain within the quick-connect fitting at the end of the fuel line. 9. Inspect fuel line fitting, locking fingers and fuel rail fitting for damage. Replace as necessary 10. Prior to connecting the fuel line to the fuel rail, check condition of both fittings. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 11. Insert the fuel line onto the fuel rail until a click is felt. 12. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 13. Install latch clip (snaps into position). If the latch clip will not fit, this indicates the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection. 14. Connect negative battery cable to battery 15. Start engine and check for leaks. W/O Pressure Test Port Fig. 19 Latch Clip Removal A special latch clip is used to secure the fuel line to the fuel rail on this particular engine. DISCONNECTION/CONNECTION AT FUEL RAIL 1. Disconnect the negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly 4. Compress clip fingers and pull clip straight up for removal. 5. Pull the fuel line from the fuel rail. 6. After disconnection the locking fingers will remain within the quick-connect fitting in the fuel rail. 7. Inspect fuel line fitting, locking fingers and fuel rail fitting for damage. Replace as necessary 8. Prior to connecting the fuel line to the fuel rail, check condition of both fittings. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 9. Insert the fuel line into the fuel rail. 10. Install latch clip with fingers down (snaps into position). The fingers should protrude below the fuel rail if properly installed. If the latch clip will not fit, this indicates the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1831 11. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 12. Connect negative battery cable to battery 13. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1832 Fuel Line Coupler: Service and Repair With Single TAB Type Fittings Fig. 11 Single-Tab Type Fitting This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly. Fig. 12 Disconnecting Single-Tab Type Fitting 4. Press the release tab on the side of fitting to release pull tab. CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be damaged. 5. While pressing the release tab on the side of the fitting, use a screwdriver to pry up the pull tab. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1833 Fig. 13 Removing Pull Tab 6. Raise the pull tab until it separates from the quick-connect fitting. Discard the old pull tab. 7. Disconnect the quick-connect fitting from the fuel system component being serviced. 8. Inspect the quick-connect fitting body and fuel system component for damage. Replace as necessary. 9. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 10. Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop on the fuel tube or component rests against back of fitting. 11. Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect fitting. 12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 13. Connect negative cable to battery. 14. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1834 Fuel Line Coupler: Service and Repair With Two TAB Type Fittings Fig. 14 Typical Two-Tab Type Quick-Connect Fitting Fuel Line Quick Connect Fitting Fuel Line Quick Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel pressure release procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retainer Type > Page 1835 DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To disconnect the quick-connect fitting, squeeze the plastic retainer tabs against the sides of the quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull the fitting from the fuel system component being serviced. The plastic retainer will remain on the component being serviced after fitting is disconnected. The 0-rings and spacer will remain in the quick- connect fitting connector body. 5. Inspect the quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 7. Insert the quick-connect fitting to the component being serviced and into the plastic retainer. when a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery 10. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fig. 3 Side View - Filter/Regulator DESCRIPTION The pressure regulator is a mechanical device that is not controlled by engine vacuum or the powertrain control module (PCM). OPERATION The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The fuel pump module contains a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm closes and excess fuel pressure is routed back into the tank through the pressure regulator. A separate fuel return line is not used with any engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 1844 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1847 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: The fuel system is under constant fuel pressure even with the engine off. Before disconnecting fuel line at fuel rail, this pressure must be released. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test - With Test Port > Page 1848 5. Connect vehicle fuel line into adapter tool 6923. Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T". 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 9. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 1855 Except CNG Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 1856 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the fuel pump relay. The Powertrain Control Module (PCM) energizes the relay by providing ground for the relay coil on circuit K31. Circuit K31 connects to cavity C19 of the PCM. When the PCM energizes the relay, the contacts close and connect circuit A14 from fuse D in the PDC to circuit A141. Circuit A141 powers the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 1857 Fuel Pump Relay: Testing and Inspection Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. Circuit A21 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation Fig. 5 Fuel Injectors - Typical (V10 Shown) The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the lower half of the two-piece intake manifold. The metal, one-piece fuel rail is not repairable. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 1861 Fuel Rail: Service and Repair Fig. 25 Fuel Rail Assembly - Typical WARNING: The fuel system is under a constant pressure (even with the engine turned off). Before servicing the fuel rail assembly, the fuel system pressure must be released. CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose. Due to the design of this connecting hose, it does use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. REMOVAL 1. Remove negative battery cable at battery. 2. Remove air cleaner. 3. Perform the fuel pressure release procedure. 4. Remove throttle body from intake manifold. Fig. 26 A/C Compressor Support Bracket - Typical 5. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 1862 Fig. 27 Fuel Injector Connectors - Typical 6. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. Fig. 28 EVAP Canister Purge Solenoid - Typical 7. Remove duty cycle EVAP canister purge solenoid/bracket assembly from intake manifold. 8. Disconnect fuel tube (line) at side of fuel rail. 9. Remove the remaining fuel rail mounting bolts. 10. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold. 11. Remove fuel rail (with injectors attached) from engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 1863 Fig 37 Fuel Injector Mounting - Typical Fig. 30 Injector Retaining Clips - Typical Injector 12. Remove the clip(s) retaining the injector(s) to fuel rail. INSTALLATION 1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold. 4. Guide each injector into the intake manifold. Be careful not to tear the injector 0-ring. 5. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder. 6. Install fuel rail mounting bolts. 7. Install EVAP canister purge solenoid to intake manifold. 8. Connect electrical connector to intake manifold air temperature sensor. 9. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. 10. Install the A/C support bracket (if equipped). 11. Install throttle body to intake manifold. 12. Install fuel tube (line) at side of fuel rail. 13. Install air cleaner. 14. Connect battery cable to battery. 15. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service and Repair > Fuel System Precaution Fuel Tank: Service and Repair Fuel System Precaution WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service and Repair > Fuel System Precaution > Page 1868 Fuel Tank: Service and Repair Fuel Tank Draining and Removal/Installation FUEL TANK DRAINING AND REMOVAL/INSTALLATION PROCEDURE DRAINING THE FUEL TANK WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. 1. Remove fuel filler cap to release any pressure in tank. 2. Perform Fuel System Pressure Release procedure. 3. Raise vehicle on hoist 4. Drain fuel into an approved, properly labeled container using one of the following procedures. WARNING: Extinguish all smoking material before serving fuel tank. Keep open flame away from fuel system components. ^ If fuel pump operates, fuel can be drained through fuel supply hose. ^ If pump does not operate, but fuel level in fuel tank is below fuel filler hose, fuel can be siphoned through fuel filler hose. The hose will have to be disconnected from filler neck. ^ If fuel tank is full and fuel pump does not operate, drain fuel from filler neck. Support fuel tank with a transmission jack. Loosen fuel tank mounting straps with passenger side fuel strap loosened slightly more than driver side strap. Lower the tank slightly. Loosen the filler neck-to-filler hose clamp. Slide clamp back on hose. Wrap shop towels around fuel filler hose to absorb any spilled fuel. Disconnect filler hose from filler neck. Drain fuel tank through filler hose REMOVAL 1. Disconnect negative cable from battery. 2. Remove fuel tank filler tube cap before disconnecting any fuel or vent lines. The fuel tank could be under a small pressure. 3. Drain fuel tank. WARNING: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement. Fuel Tank Filler Assembly 4. Raise vehicle on hoist and disconnect all vent and filler hoses. Remove the vent hoses from the hose routing bracket attached to the top of the frame. 5. Place a transmission jack under the center of the fuel tank, and apply slight pressure. 6. Remove nuts from inboard ends of the two mounting straps. Lower the tank far enough to allow the fuel pump module electrical connector to be disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service and Repair > Fuel System Precaution > Page 1869 Fuel Tank Mounting To Frame Rail 7. Disconnect the fuel supply line from the fuel pump module. 8. Disconnect the fuel vapor line from rollover valve. 9.. Lower tank from vehicle. INSTALLATION 1. Place fuel tank on transmission jack and raise up enough to connect the fuel line, electrical connector and vapor hose to the fuel pump module. 2. Continue raising tank into position in cross-members and connect the two end retaining straps. Remove the transmission jack. Tighten all straps to 35 ft-lbs (47 Nm) torque. Do not overtighten retaining strap nuts. 3. Connect vent/fill hoses. 4. Refill fuel tank and inspect all hoses and lines for leaks. 5. Connect negative cable to battery. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 1873 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 1874 Fuel Tank Unit: Description and Operation Fig. 1 Top View Fuel Pump Module - Gas Powered Engines - Typical Fig. 2 Fuel Pump Module Components - Gas Powered Engines - Typical The fuel pump module on all gas powered engines is installed in the top of the fuel tank. The fuel pump module contains the following: ^ A combination fuel filter/fuel pressure regulator ^ Electric fuel pump ^ Fuel pump reservoir ^ A separate in-tank fuel filter ^ Pressure relief/rollover valve ^ Fuel gauge sending unit ^ Fuel supply line connection ^ Auxiliary fuel supply fitting (not all engines) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 1875 Fuel Tank Unit: Service and Repair REMOVAL WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released. CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced. 1. Drain the fuel tank. 2. Remove fuel tank. Fig. 22 Top View Of Fuel Pump Module Fig. 24 Locknut Removal/Installation - Typical 3. The plastic fuel pump module locknut is threaded onto the fuel tank. Install Special Tool 6856 to the fuel pump module locknut and remove locknut. The fuel pump module will spring up when the locknut is removed. 4. Remove module from fuel tank. INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced. 1. Using a new gasket, position fuel pump module into the opening in fuel tank. 2. Position a new locknut over the top of fuel pump module. 3. Install Special Tool 6856 onto the locknut. 4. Tighten locknut to 54 N.m (40 ft. lbs.) torque. 5. Install fuel tank. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1879 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1880 Idle Speed/Throttle Actuator - Electronic: Description and Operation The Powertrain Control Module (PCM) operates the Idle Air Control motor through four circuits; K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. - Circuit K39 connects to cavity A19 of the PCM connector. - Circuit K4O connects to cavity A11 of the PCM connector. - Circuit K59 connects to cavity A20 of the PCM connector. - Circuit K60 connects to cavity A10 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1881 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 1882 Idle Speed/Throttle Actuator - Electronic: Adjustments Fig. 33 Throttle Body And Sensor Locations A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1886 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1887 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1888 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1896 Except CNG Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1897 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the fuel pump relay. The Powertrain Control Module (PCM) energizes the relay by providing ground for the relay coil on circuit K31. Circuit K31 connects to cavity C19 of the PCM. When the PCM energizes the relay, the contacts close and connect circuit A14 from fuse D in the PDC to circuit A141. Circuit A141 powers the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1898 Fuel Pump Relay: Testing and Inspection Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. Circuit A21 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1902 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1903 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 supplies battery voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A14 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1904 Automatic Shut Down (ASD) Relay: Testing and Inspection Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1909 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1910 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1911 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1912 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation Throttle Body: Description and Operation DESCRIPTION The throttle position sensor (TPS), idle air control (IAC) motor and manifold absolute pressure sensor (MAP) are attached to the throttle body The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). OPERATION Fig. 30 Throttle Body Fig. 31 Air Control Passage Filtered air from the air cleaner enters the intake manifold through the throttle body. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. The throttle body is mounted on the intake manifold. It contains an air control passage controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 1916 Throttle Body: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 1917 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 1918 Throttle Body: Service and Repair A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). REMOVAL 1. Remove the air cleaner. Fig. 40 Sensor And IAC Location - Typical 2. Disconnect throttle body electrical connectors at Manifold Absolute Pressure (MAP) sensor, Idle Air Control (IAC) motor and Throttle Position Sensor (TPS). 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to Accelerator Cable/Service and Repair. Fig. 30 Throttle Body 5. Remove four throttle body mounting bolts. 6. Remove throttle body from intake manifold. 7. Discard old throttle body-to-intake manifold gasket. INSTALLATION 1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle body-to-intake manifold gasket. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 1919 3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 N.m (200 in. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body 7. Install electrical connectors. 8. Install air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Fig. 37 Cable Removal/Installation CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. REMOVAL 1. From inside the vehicle, hold up the accelerator pedal. Remove the plastic cable retainer and throttle cable core wire from upper the end of the pedal arm. The plastic cable retainer snaps into pedal the arm. 2. Remove the cable core wire at the pedal arm. 3. Remove the air cleaner housing. 4. From inside the vehicle, pinch both sides of the plastic cable housing retainer tabs at the dash panel. 5. Remove cable housing from dash panel and pull the cable into the engine compartment. Fig. 40 Throttle Cable At Throttle Body 6. Remove the throttle cable socket at throttle lever ball.(snaps off). 7. Remove cable housing at throttle body mounting bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on the tab only enough to release the cable from the bracket. Lift the cable housing straight up from bracket while pressing on release tab. Remove throttle cable from vehicle. INSTALLATION 1. Connect cable end socket to throttle body lever ball (snaps on). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 1923 2. Connect cable to throttle body mounting bracket (push down and lock). 3. Install the remaining cable housing end into and through the dash panel opening (snaps into position). The two plastic pinch tabs should lock the cable to dash panel. 4. From inside the vehicle, hold up the accelerator pedal. Install the throttle cable core wire and plastic cable retainer into and through the upper end of the pedal arm (the plastic retainer is snapped into the pedal arm). When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm. Align the index slot on the plastic cable retainer to this index tab. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1927 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1928 Throttle Position Sensor: Description and Operation CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1929 Throttle Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1930 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications 1988 - 1996 3.9L (238) Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations 1988 - 1996 3.9L (238) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1942 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1945 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1946 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1947 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1951 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 1954 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 1957 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 1958 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1974 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1975 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1976 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1977 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1978 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1979 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1985 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1986 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1987 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1988 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1989 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1990 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 1991 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 1992 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 1993 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations Coil Location -- Typical (Light Duty Shown) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 1997 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Circuit Description Ignition Coil: Description and Operation Circuit Description CIRCUIT OPERATION When the Powertrain Control Module (PCM) grounds the Automatic Shut Down (ASD) relay, the contacts close and connect circuits A14 and A142. Circuit A142 supplies battery voltage to the ignition coil. The PCM controls the ground path for the ignition coil on circuit K19. Circuit K19 connects to cavity A7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Circuit Description > Page 2000 Ignition Coil: Description and Operation Ignition Coil DESCRIPTION Battery voltage is supplied to the ignition coil positive terminal from the Auto Shutdown (ASD) relay. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. OPERATION The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information Ignition Coil: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 2003 Ignition Coil: Testing and Inspection Ignition Coil Test Fig. 13 Ignition Coil - Typical The ignition coil is designed to operate without an external ballast resistor. Ignition Coil Resistance Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturer's instructions. Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer to the Ignition Coil Resistance chart. If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace cable if it has been burned or damaged. Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will cause the coil to fail. If the secondary coil cable shows any signs of damage, it should be replaced with a new cable and new terminal. Carbon tracking on the old cable can cause arcing and the failure of a new ignition coil. For more information, see Powertrain Management/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 2004 Ignition Coil: Service and Repair 1. Disconnect primary wiring from ignition coil. 2. Disconnect ignition coil secondary spark plug cable from ignition coil. 3. Remove ignition coil from mounting bracket. 4. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2009 Camshaft Position Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Camshaft Position Sensor: Description and Operation Sensor Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 2012 Camshaft Position Sensor: Description and Operation Helpful Information CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2013 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2014 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2018 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Sensor Operation > Page 2021 Crankshaft Position Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Component Test > Page 2024 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Page 2025 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2029 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2030 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2031 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2032 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Description and Operation Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2038 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2039 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2040 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2041 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2042 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Oil or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2043 Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced, or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Wet Fouling or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 2044 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 2045 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 0.89 mm (0.035 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2060 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2066 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2073 Torque Converter Clutch Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 2079 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2097 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2098 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2104 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2105 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2106 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2110 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2111 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 2117 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2126 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2132 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2136 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2137 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2141 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 2146 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 2147 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2151 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 2157 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/Erroneous DTC P1398 (or $BA) NUMBER: 25-003-01 GROUP: Emissions DATE: Feb. 23, 2001 SUBJECT: Erroneous DTC P1398 (or $BA) - No Crank Sensor Learn OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 96Cal18 or 97Cal18). MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR/BE)Ram Truck 1997 (TJ) Wrangler 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SYMPTOM/CONDITION: A customer may experience a MIL (Check Engine Lamp) illumination due to an erroneous DTC P1398 - No Crank Sensor Learn. This DTC may also be displayed as a $BA - Adaptive Numerator at Limit. This condition may be caused by a momentary drop in the supply voltage to the powertrain control module. This condition may occur when a normal, or higher, electrical load is applied to the battery. A momentary drop in the supply voltage to the PCM may be caused by a marginal battery or poor electrical connections from the battery to the PCM. The condition may be further aggravated by cold ambient temperatures or when the vehicle has been left unused for an extended period of time. DIAGNOSIS: 1. Verify the calibration level of the PCM software. If the PCM software is at 96Cal18 or 97Cal18, or higher, then this TSB does not apply. Further diagnosis is required. 2. If PCM software is earlier (lower or less) than either 96Cal18 or 97Cal18, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) > Page 2166 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS BETWEEN MODULES. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM LAST, AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASE. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the Powertrain Control Module and cover the label with the clear plastic overlay. 3. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 2171 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 2172 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2177 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2178 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2179 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition Technical Service Bulletin # 18-24-98 Date: 980731 PCM - Light Spark Knock Condition NO: 18-24-98 GROUP: Vehicle Performance DATE: Jul. 31, 1998 SUBJECT: Light Spark Knock Timing Retard Feature MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) GrandCherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES EOUIPPED WITH A 2.5L, 4.OL, 3.9L, 5.2L AND 5.9L LIGHT DUTY GASOLINE ENGINES. SYMPTOM/CONDITION: Some vehicles may exhibit light spark knock with a warm engine under load. DISCUSSION: Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is completed, spark advance/retard may be adjusted. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Select DRB III(R) stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance will be available. Use the arrow keys to retard timing in 20 increments to a maximum of A°. When the DRB III(R) screen reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard. NOTE: THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT. After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone. This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, funher diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO ScanTool (DRBIII(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1165 OR HIGHER MUST BE INSTALLED. THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 2184 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the POM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 2185 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2190 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2191 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2192 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2193 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2194 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2195 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns PROM - Programmable Read Only Memory: Customer Interest PCM - Erroneous Mil ON/Driveability Concerns NO: 18-03-97 GROUP: Vehicle Performance DATE: Jan. 24, 1997 SUBJECT: Erroneous MIL Illumination/ Driveability Improvements MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (XJ) Cherokee 1996 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Applies to vehicles with the applications and conditions: DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's or those listed above are present and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns > Page 2200 REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns > Page 2201 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-94 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning PROM - Programmable Read Only Memory: Customer Interest TCM - Erroneous DTC A4/Actuator Tests Not Functioning NO: 21-07-96 GROUP: Transmission DATE: May 3, 1996 SUBJECT: Erroneous DTC A4 And DRB III Transmission Actuator Test Corrected MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS ONLY. SYMPTOM/CONDITION: When diagnosing a vehicle utilizing the Mopar Diagnostic System (MDS)/Scan Tool (DRBIII) DTC HEX A4 (Trans Temp Sensor No Temp Rise After Start - MIL 37) may be encountered. Also the DRBIII/MDS may not be able to perform the "Actuator Test" for the Torque Converter Clutch (TCC) solenoid properly. DISCUSSION: The Powertrain Control Module (PCM) logic may set DTC HEX A4 without a malfunctioning transmission temperature sensor. The transmission temperature sensor is an input to the PCM to aid in controlling the operation of the TCC. when the transmission temperature sensor fails and DTC HEX A4 is set the PCM will rely on information from the Engine Coolant Temperature (ECT) sensor to control TCC operation. Due to the PCM using the ECT sensor as a back-up sensor our customers will not complain of any malfunction of the TCC operation even with a failed transmission temperature sensor nor will the Check Engine Lamp (MIL) illuminate. In addition the test designed to identify TCC malfunctions utilizing the DRBIII/MDS function called Actuator Tests" does not function properly due to software problems within the PCM. The test was designed to set governor pressure to a maximum level and duty cycle the TCC solenoid. This would allow the technician to check hydraulic pressure of the TCC circuit without having to drive the vehicle. Because of a software malfunction in the PCM the PCM would not initiate the governor pressure solenoid during the test, thus requiring the vehicle to be driven for testing. Please perform updates to the PCM for any vehicle listed that you encounter. The update will correct both conditions DIAGNOSIS: Using the MDS or the DRBIII and appropriate Diagnostic Procedure Manual verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTCs) are present record them on the repair order for future reference and repair before proceeding with this bulletin NOTE: IT IS NOT NECESSARY TO ALSO UPDATE THE PCM FOR CONDITIONS LISTED IN TSB 24-03-96 DATED FEB. 23, 1996, 08-07-96 DATED MARCH 8, 1996, OR 18-03-96 REV. B DATED APRIL 19, 1996. PCM UPDATES PERFORMED WITH RELEASE 19 AND TIL 1105 WILL UPDATE THE SOFTWARE TO THE MOST RECENT LEVEL AND INCLUDE ALL PREVIOUS REVISIONS. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the PCM with new software (calibration change). NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning > Page 2206 MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1105 OR HIGHER INSTALLED. 1. Connect the MDS to the DRBIII and connect the DRBIII to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS7 then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRBIII on the MDS then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning > Page 2207 08-19-50-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns PROM - Programmable Read Only Memory: Customer Interest PCM - Erroneous MIL Illumination/Driveability Concerns NO: 18-03-96 Rev. B GROUP: Vehicle Performance DATE: Apr. 19, 1996 SUBJECT: Erroneous MIL Illumination and/or Driveability Concerns THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-96 REV. A DATED FEB. 16, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL POWERTRAIN CONTROL MODULES (PCM) ARE SUPPORTED WITH MOPAR DIAGNOSTIC SYSTEM (MDS) RELEASE 19 AND TIL 1105. ADDITIONALLY, IF A PREVIOUS PCM UPDATE FAILED TO CORRECT A CONDITION FOR ERRONEOUS DIAGNOSTIC TROUBLE CODES (DTC) 76 AND 77, PERFORM A REFLASH. ENHANCEMENTS TO THE PCM SOFTWARE WERE MADE FROM TIL 1100 TO 1105. MODELS: 1996 (AB) Ram Van/wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (XJ) Cherokee 1996 (ZJ) Grand Cherokee 1997 (TJ) Wrangler SYMPTOM/CONDITION: The following is a list of PCM updates for erroneous MIL (Check Engine Lamp) illumination and/or driveability concerns. Please perform updates to the PCM for any vehicle listed above that you encounter. NOTE: IT IS NOT NECESSARY TO ALSO UPDATE THE PCM FOR CONDITIONS LISTED IN TSB 08-07-96 DATED MARCH 8, 1996 OR 24-03-96 DATED FEB. 23, 1996. PCM UPDATES PERFORMED WITH RELEASE 19 AND TIL 1105 WILL UPDATE THE SOFTWARE TO THE MOST RECENT LEVEL AND INCLUDE ALL PREVIOUS REVISIONS. NOTE: IF YOU ENCOUNTER A DTC 76, YOU MUST VERIFY FUEL SYSTEM PRESSURE. USE THE APPROPRIATE SERVICE MANUAL FOR INFORMATION ON FUEL PRESSURE TESTER INSTALLATION. THE FUEL PRESSURE MUST BE 49 PSI +/- 2 PSI. IF THE FUEL PRESSURE IS OUT OF SPECIFICATION, REPAIR OR REPLACE ANY FUEL SYSTEM MALFUNCTIONING COMPONENTS AND PERFORM THE PCM UPDATE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2212 DODGE TRUCKS JEEP VEHICLES DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If any of the above conditions exist, perform the Repair Procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2213 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1105 OR HIGHER INSTALLED. 1. Connect the MDS to the DRBIII and connect the DRBIII to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRBIII on the MDS then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2214 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-45-91 0.5 Hrs. Labor Operation No.: Fuel Pressure Test For DTC 76 and Reprogram Powertrain Control Module 08-19-45-92 1.1 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 240396 > Feb > 96 > PCM - A/C Does Not Cool PROM - Programmable Read Only Memory: Customer Interest PCM - A/C Does Not Cool NO: 24-03-96 GROUP: Air Conditioning DATE: Feb. 23, 1996 SUBJECT: A/C Does Not Cool MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (ZJ) Grand Cherokee NOTE: THIS BULLETIN AFFECTS VEHICLES EQUIPPED WITH A 5.2L, 5.9L (GAS ENGINE ONLY), OR 8.0L ENGINES ONLY. SYMPTOM/CONDITION: Customers complaints of lack of cooling may be related to a condition where the A/C clutch either remains engaged at Wide Open Throttle (WOT) or remains disengaged after a WOT operation. NOTE: THIS CONDITION OCCURS ONLY AT ENGINE SPEEDS OF APPROXIMATELY 3000 RPM. This condition could cause the A/C evaporator to freeze up or may cause the compressor to not circulate refrigerant through the A/C system. This condition could be caused by the PCM leaving the A/C clutch relay energized or de-energized too long. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If the above condition exists, perform the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII ) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1101 OR HIGHER INSTALLED. 1. Connect the MDS and DRBIII to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: YOU MAY BE REQUIRED TO REPROGRAM THE VIN AND ALL OPTIONS INTO THE UPDATED PCM. THIS WOULD BE THE SAME PROCEDURE THAT YOU WOULD USE IF YOU ARE INSTALLING A NEW PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 240396 > Feb > 96 > PCM - A/C Does Not Cool > Page 2219 NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-44-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2225 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2226 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2227 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2228 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2229 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2230 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2231 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2232 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2233 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2234 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2235 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2236 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2237 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2238 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2239 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2240 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2241 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2242 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2243 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/Erroneous DTC P1398 (or $BA) NUMBER: 25-003-01 GROUP: Emissions DATE: Feb. 23, 2001 SUBJECT: Erroneous DTC P1398 (or $BA) - No Crank Sensor Learn OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 96Cal18 or 97Cal18). MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR/BE)Ram Truck 1997 (TJ) Wrangler 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SYMPTOM/CONDITION: A customer may experience a MIL (Check Engine Lamp) illumination due to an erroneous DTC P1398 - No Crank Sensor Learn. This DTC may also be displayed as a $BA - Adaptive Numerator at Limit. This condition may be caused by a momentary drop in the supply voltage to the powertrain control module. This condition may occur when a normal, or higher, electrical load is applied to the battery. A momentary drop in the supply voltage to the PCM may be caused by a marginal battery or poor electrical connections from the battery to the PCM. The condition may be further aggravated by cold ambient temperatures or when the vehicle has been left unused for an extended period of time. DIAGNOSIS: 1. Verify the calibration level of the PCM software. If the PCM software is at 96Cal18 or 97Cal18, or higher, then this TSB does not apply. Further diagnosis is required. 2. If PCM software is earlier (lower or less) than either 96Cal18 or 97Cal18, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) > Page 2248 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS BETWEEN MODULES. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM LAST, AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASE. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the Powertrain Control Module and cover the label with the clear plastic overlay. 3. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 2253 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 2254 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2259 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2260 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 2261 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition Technical Service Bulletin # 18-24-98 Date: 980731 PCM - Light Spark Knock Condition NO: 18-24-98 GROUP: Vehicle Performance DATE: Jul. 31, 1998 SUBJECT: Light Spark Knock Timing Retard Feature MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) GrandCherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES EOUIPPED WITH A 2.5L, 4.OL, 3.9L, 5.2L AND 5.9L LIGHT DUTY GASOLINE ENGINES. SYMPTOM/CONDITION: Some vehicles may exhibit light spark knock with a warm engine under load. DISCUSSION: Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is completed, spark advance/retard may be adjusted. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Select DRB III(R) stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance will be available. Use the arrow keys to retard timing in 20 increments to a maximum of A°. When the DRB III(R) screen reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard. NOTE: THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT. After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone. This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, funher diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO ScanTool (DRBIII(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1165 OR HIGHER MUST BE INSTALLED. THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 2266 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the POM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 2267 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2272 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2273 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2274 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2275 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2276 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2277 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Erroneous Mil ON/Driveability Concerns NO: 18-03-97 GROUP: Vehicle Performance DATE: Jan. 24, 1997 SUBJECT: Erroneous MIL Illumination/ Driveability Improvements MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (XJ) Cherokee 1996 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Applies to vehicles with the applications and conditions: DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's or those listed above are present and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns > Page 2282 REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180397 > Jan > 97 > PCM - Erroneous Mil ON/Driveability Concerns > Page 2283 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-94 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning PROM - Programmable Read Only Memory: All Technical Service Bulletins TCM - Erroneous DTC A4/Actuator Tests Not Functioning NO: 21-07-96 GROUP: Transmission DATE: May 3, 1996 SUBJECT: Erroneous DTC A4 And DRB III Transmission Actuator Test Corrected MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS ONLY. SYMPTOM/CONDITION: When diagnosing a vehicle utilizing the Mopar Diagnostic System (MDS)/Scan Tool (DRBIII) DTC HEX A4 (Trans Temp Sensor No Temp Rise After Start - MIL 37) may be encountered. Also the DRBIII/MDS may not be able to perform the "Actuator Test" for the Torque Converter Clutch (TCC) solenoid properly. DISCUSSION: The Powertrain Control Module (PCM) logic may set DTC HEX A4 without a malfunctioning transmission temperature sensor. The transmission temperature sensor is an input to the PCM to aid in controlling the operation of the TCC. when the transmission temperature sensor fails and DTC HEX A4 is set the PCM will rely on information from the Engine Coolant Temperature (ECT) sensor to control TCC operation. Due to the PCM using the ECT sensor as a back-up sensor our customers will not complain of any malfunction of the TCC operation even with a failed transmission temperature sensor nor will the Check Engine Lamp (MIL) illuminate. In addition the test designed to identify TCC malfunctions utilizing the DRBIII/MDS function called Actuator Tests" does not function properly due to software problems within the PCM. The test was designed to set governor pressure to a maximum level and duty cycle the TCC solenoid. This would allow the technician to check hydraulic pressure of the TCC circuit without having to drive the vehicle. Because of a software malfunction in the PCM the PCM would not initiate the governor pressure solenoid during the test, thus requiring the vehicle to be driven for testing. Please perform updates to the PCM for any vehicle listed that you encounter. The update will correct both conditions DIAGNOSIS: Using the MDS or the DRBIII and appropriate Diagnostic Procedure Manual verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTCs) are present record them on the repair order for future reference and repair before proceeding with this bulletin NOTE: IT IS NOT NECESSARY TO ALSO UPDATE THE PCM FOR CONDITIONS LISTED IN TSB 24-03-96 DATED FEB. 23, 1996, 08-07-96 DATED MARCH 8, 1996, OR 18-03-96 REV. B DATED APRIL 19, 1996. PCM UPDATES PERFORMED WITH RELEASE 19 AND TIL 1105 WILL UPDATE THE SOFTWARE TO THE MOST RECENT LEVEL AND INCLUDE ALL PREVIOUS REVISIONS. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the PCM with new software (calibration change). NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning > Page 2288 MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1105 OR HIGHER INSTALLED. 1. Connect the MDS to the DRBIII and connect the DRBIII to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS7 then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRBIII on the MDS then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 210796 > May > 96 > TCM - Erroneous DTC A4/Actuator Tests Not Functioning > Page 2289 08-19-50-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Erroneous MIL Illumination/Driveability Concerns NO: 18-03-96 Rev. B GROUP: Vehicle Performance DATE: Apr. 19, 1996 SUBJECT: Erroneous MIL Illumination and/or Driveability Concerns THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-96 REV. A DATED FEB. 16, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL POWERTRAIN CONTROL MODULES (PCM) ARE SUPPORTED WITH MOPAR DIAGNOSTIC SYSTEM (MDS) RELEASE 19 AND TIL 1105. ADDITIONALLY, IF A PREVIOUS PCM UPDATE FAILED TO CORRECT A CONDITION FOR ERRONEOUS DIAGNOSTIC TROUBLE CODES (DTC) 76 AND 77, PERFORM A REFLASH. ENHANCEMENTS TO THE PCM SOFTWARE WERE MADE FROM TIL 1100 TO 1105. MODELS: 1996 (AB) Ram Van/wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (XJ) Cherokee 1996 (ZJ) Grand Cherokee 1997 (TJ) Wrangler SYMPTOM/CONDITION: The following is a list of PCM updates for erroneous MIL (Check Engine Lamp) illumination and/or driveability concerns. Please perform updates to the PCM for any vehicle listed above that you encounter. NOTE: IT IS NOT NECESSARY TO ALSO UPDATE THE PCM FOR CONDITIONS LISTED IN TSB 08-07-96 DATED MARCH 8, 1996 OR 24-03-96 DATED FEB. 23, 1996. PCM UPDATES PERFORMED WITH RELEASE 19 AND TIL 1105 WILL UPDATE THE SOFTWARE TO THE MOST RECENT LEVEL AND INCLUDE ALL PREVIOUS REVISIONS. NOTE: IF YOU ENCOUNTER A DTC 76, YOU MUST VERIFY FUEL SYSTEM PRESSURE. USE THE APPROPRIATE SERVICE MANUAL FOR INFORMATION ON FUEL PRESSURE TESTER INSTALLATION. THE FUEL PRESSURE MUST BE 49 PSI +/- 2 PSI. IF THE FUEL PRESSURE IS OUT OF SPECIFICATION, REPAIR OR REPLACE ANY FUEL SYSTEM MALFUNCTIONING COMPONENTS AND PERFORM THE PCM UPDATE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2294 DODGE TRUCKS JEEP VEHICLES DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If any of the above conditions exist, perform the Repair Procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2295 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1105 OR HIGHER INSTALLED. 1. Connect the MDS to the DRBIII and connect the DRBIII to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRBIII on the MDS then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180396B > Apr > 96 > PCM - Erroneous MIL Illumination/Driveability Concerns > Page 2296 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-45-91 0.5 Hrs. Labor Operation No.: Fuel Pressure Test For DTC 76 and Reprogram Powertrain Control Module 08-19-45-92 1.1 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 240396 > Feb > 96 > PCM - A/C Does Not Cool PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - A/C Does Not Cool NO: 24-03-96 GROUP: Air Conditioning DATE: Feb. 23, 1996 SUBJECT: A/C Does Not Cool MODELS: 1996 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 (BR) Ram Truck 1996 (ZJ) Grand Cherokee NOTE: THIS BULLETIN AFFECTS VEHICLES EQUIPPED WITH A 5.2L, 5.9L (GAS ENGINE ONLY), OR 8.0L ENGINES ONLY. SYMPTOM/CONDITION: Customers complaints of lack of cooling may be related to a condition where the A/C clutch either remains engaged at Wide Open Throttle (WOT) or remains disengaged after a WOT operation. NOTE: THIS CONDITION OCCURS ONLY AT ENGINE SPEEDS OF APPROXIMATELY 3000 RPM. This condition could cause the A/C evaporator to freeze up or may cause the compressor to not circulate refrigerant through the A/C system. This condition could be caused by the PCM leaving the A/C clutch relay energized or de-energized too long. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If the above condition exists, perform the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRBIII ) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRBIII ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL 1101 OR HIGHER INSTALLED. 1. Connect the MDS and DRBIII to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRBIII will prompt the operator for any action needed during the remainder of the programming process. NOTE: YOU MAY BE REQUIRED TO REPROGRAM THE VIN AND ALL OPTIONS INTO THE UPDATED PCM. THIS WOULD BE THE SAME PROCEDURE THAT YOU WOULD USE IF YOU ARE INSTALLING A NEW PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 240396 > Feb > 96 > PCM - A/C Does Not Cool > Page 2301 NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-44-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2307 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2308 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2309 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2310 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2311 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2312 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2313 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2314 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2315 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2316 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2317 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2318 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2319 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2320 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2321 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2322 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2323 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2324 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2325 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2340 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2346 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2353 Torque Converter Clutch Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2367 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2373 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2379 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2385 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2392 Torque Converter Clutch Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse Technical Service Bulletin # 21-11-97A Date: 970905 A/T - Buzz Sound Shifting Into reverse NO: 21-11-97 Rev.A GROUP: Transmission DATE: Sep. 5, 1997 SUBJECT: Reverse Buzz (46RE) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-11-97 WITH AN EFFECTIVE DATE OF AUG. 15, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO THE REVERSE BAND ADJUSTMENT PROCEDURE. MODELS: 1996-1997 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996-1997 (BR) Ram Truck SYMPTOM/CONDITION: Buzz sound when shifting into reverse. This condition may be more noticeable on a cold vehicle that has been parked outside overnight. DIAGNOSIS: Starting with a cold vehicle (parked outside overnight), start the engine and shift the transmission from park to reverse and from drive to reverse several times while listening for a buzz sound when in reverse. The buzz may be more noticeable with the windows down or from outside the cab. If the buzz occurs when in reverse, perform the Repair Procedure. PARTS REQUIRED: 1 04897877AA Package, Reverse Buzz 1 02464324 Gasket, Pan AR (Qts) 04798233 Fluid, ATF +2 Type 7176 AR (1) 03515996 Filter, fluid AR (1) 06030910 Seal, Reaction Pin REPAIR PROCEDURE: This bulletin involves removing the overdrive unit, propeller shafts, and (transfer case if applicable) and replacing the rear band adjusting lever, reaction lever and strut with high ratio components along with replacement of the regulator valve pressure plug and sleeve. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-15-05-96 2.7 Hrs. Optional Equipment: 21-15-05-60 4X4 Equipped BR 1.7 Hrs. 4X4 Equipped AN 1.5 Hrs. FAILURE CODE: P8 - New Part Propeller Shaft and Transfer Case (If Equipped) 1. Shift the transmission into park and the transfer case into neutral. 2. Record all radio presets and disconnect the negative battery cable. 3. Raise and support the vehicle on a hoist. 4. Remove the transfer case skid plate if so equipped. 5. Mark the front and rear propeller shafts and U-joints for alignment reference and remove the shafts. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2401 6. Disconnect the wires at the vehicle speed sensor. 7. Disconnect the vent hose and vacuum harness at the transfer case switch, if equipped. 8. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easier access. 9. Support transmission with a jack stand. 10. Remove the rear cross member. 11. Support the transfer case with a suitable jack (secure the transfer case to the jack with safety chains). 12. Remove nuts attaching transfer case to the transmission. 13. Move transfer case rearward until it is free of the transmission output shaft. 14. Lower the jack and move the transfer case from under the vehicle. Pan/Filter/Valve Body Removal 1. Remove the gear shift and throttle levers form shaft of valve body manual lever. 2. Disconnect wires at solenoid case connector. 3. Position a drain pan beneath the transmission oil pan. 4. Loosen the oil pan bolts to allow the transmission to drain into the drain pan. 5. While supporting the oil pan, remove all bolts and lower the oil pan away from the transmission. Drain the remaining fluid into the drain pan. 6. Remove the fluid filter from the valve body. 7. Remove the valve body to transmission case bolts. 8. Lower valve body enough to remove accumulator piston and springs. 9. Work manual lever shaft and electrical connector out of transmission case. 10. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. Overdrive Removal NOTE: THE OVERDRIVE UNIT MUST BE FULLY SUPPORTED DURING REMOVAL. THIS IS NECESSARY TO PREVENT DAMAGING THE INTERMEDIATE SHAFT. DO NOT ALLOW THE SHAFT TO SUPPORT THE ENTIRE WEIGHT OF THE OVERDRIVE UNIT. 1. Remove the bolts attaching the overdrive unit to the transmission. NOTE: USE CARE WHEN SEPARATING THE OVERDRIVE UNIT FROM THE TRANSMISSION TO PREVENT GASKET DAMAGE. 2. Carefully slide the overdrive unit off the intermediate shaft. Do not tilt unit during removal. Keep the unit as level as possible. 3. Insert alignment tool 6227-2 into the splines of planetary gear and overrunning clutch to prevent the splines from rotating out of alignment. NOTE: IF MISALIGNMENT OCCURS, THE OVERDRIVE UNIT WILL HAVE TO BE DISASSEMBLED IN ORDER TO RE-ALIGN THE SPLINES. 4. Remove and retain the overdrive piston thrust bearing and spacer. NOTE: THE BEARING MAY REMAIN ON THE PISTON OR IN THE CLUTCH HUB DURING REMOVAL. Reverse Band Levers and Strut Replacement 1. Loosen the locknut and unscrew the reverse band adjusting screw (but do not remove the screw). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2402 2. Using a small punch and hammer, tap the reverse band reaction pin out from the front until it can be removed. Remove the shaft so both levers can be removed (Figure 1). Discard the removed levers and strut. 3. Inspect the shaft "0" rings and replace them if necessary p/n 06030910. 4. Compress the rear servo piston enough to permit snap ring removal. 5. Remove the servo piston snap ring. Use caution when removing to prevent servo bore scratching. 6. Remove the rear servo retainer, spring, and piston assembly (Figure 2). 7. Measure the distance from the end of the rear servo piston plug to the face of the piston (Figure 3). Record this measurement for future use when adjusting the rear band. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2403 8. Re-install the rear servo retainer, spring, and piston into the transmission. Secure it with the snap ring. 9. Install the band adjusting screw (from old lever) and partially install the (new) band adjusting lever by pushing the reaction shaft through one flange of the lever p/n 04897877AA. 10. Using PETROLEUM JELLY, assemble the replacement strut and reaction lever p/n 04897877AA. 11. Install the assembled strut and reaction lever inside the adjusting lever and push the reaction pin completely through the assembly until it is flush with the back of the transmission case. NOTE: MAKE SURE THE STRUT IS INSTALLED CORRECTLY INTO THE LOW REVERSE BAND. TO CHECK INSTALLATION, APPLY THE ADJUSTING LEVER BY HAND AND NOTE THE MOVEMENT OF THE BAND. IF IT IS NOT INSTALLED CORRECTLY, LOOSEN THE ADJUSTING SCREW UNTIL THE STRUT CAN BE PUT IN PLACE WITHOUT DISASSEMBLING THE LEVERS. NOTE: DO NOT TIGHTEN THE ADJUSTING SCREW AT THIS POINT. Overdrive Installation 1. Inspect the gasket to make sure it was not damaged during removal. If damaged, refer to the service manual for replacement. 2. Install the thrust bearing and spacer in overdrive unit sliding hub. Use petroleum jelly to hold it in place. 3. Carefully slide the alignment tool 6227-2 out of the unit. 4. Raise the overdrive unit and carefully slide it straight onto the intermediate shaft. 5. Install the attaching bolts and tighten the bolts to 34 Nm (25 ft lbs) in a diagonal pattern. 6. Install the transmission mount and tighten to 41 Nm (30 ft lbs). 7. Connect speed sensors and speedometer wires. Reverse Band Adjustment 1. Remove the plug in the rear servo test port. 2. Based on the measurement taken in step 7 of REVERSE BAND LEVERS AND STRUT REPLACEMENT select the appropriate size drill bit from the table: 3. Insert the butt end of the appropriate drill bit into the test port 3 inches deep and centered beneath the servo plug. 4. With the bit properly located, tighten the reverse band adjusting screw to 8 Nm (72 in lbs) and back off the screw 2 1/4 turns. **5. Loosen the adjusting screw and repeat step 4. While holding the adjusting screw, tighten the adjusting screw lock nut to 34 Nm (25 ft lbs).** 6. Remove the drill bit and replace the rear servo test port plug. Pressure Plug and Sleeve Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2404 1. Without disassembling the valve body, remove the regulator valve cover hiding the pressure plug and sleeve (Figure 4). 2. Remove the existing pressure plug and sleeve and discard the old parts. Install the replacement parts from the kit. 3. Reinstall the regulator valve cover and tighten the screws. RE-Installation of Remaining Components 1. Place valve body manual lever in low (1 position) so ball on rod will be easier to install in sprag. 2. Position valve body in case and work end of park lock rod into and through pawl sprag. Move rod to check engagement. 3. Install accumulator piston and springs. The inner spring has a smaller diameter. 4. Swing valve body over piston and outer spring to hold it in place. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 5. Seat valve body in case and install the bolts. Alternately tighten each bolt to 11 Nm (100 in lbs). 6. Install the fluid filter. Replace as necessary p/n 03515996. 7. Install throttle and gearshift levers on valve body manual shaft. 8. Check and adjust front band if necessary. 9. Connect solenoid case connector wires. 10. Install the oil pan with a new gasket p/n 02464324. Tighten the pan bolts to 17 Nm (13 ft lbs). 11. If applicable, mount the transfer case on a jack and secure with chains. 12. Align transfer case and transmission shaft and install transfer case on transmission. Tighten the transfer case bolts to 35 Nm (26 ft lbs). 13. Connect the vent hose. 14. Connect indicator switch harness to transfer case, if necessary. Secure wire harness to clips on transfer case. 15. Align and connect propeller shafts. Tighten attaching bolts to 19 Nm (170 in lbs). 16. Lower vehicle. 17. Fill transmission with Mopar ATF +2, type 7176 fluid p/n 04798233. 18. Reconnect the negative battery cable and set radio presets recorded in step 2 of the first procedure. 19. Adjust the gearshift linkage and throttle valve cable if necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 211995A > Jan > 96 > A/T - Slips In Reverse At Mid Throttle Band: Customer Interest A/T - Slips In Reverse At Mid Throttle NO: 21-19-95 Rev. A GROUP: Transmission DATE: Jan 5, 1996 SUBJECT: Automatic Transmission Slips In Reverse At Mid Throttle NOTE: This bulletin supersedes Technical Service Bulletin 21-19-95 dated November 24, 1995 which should be removed from your files. The labor operation number coverage statements for both 4X2 and 4X4 vehicles has been revised to fit the repair and is marked with **asterisks** MODELS: 1996 (AB) Ram Van/wagon 1996 (AN) Dakota 1996 (BR) Ram Truck NOTE: This bulletin applies to vehicles built with the 36RH and 46RE transmissions only built prior to December 1, 1995 (MDH 12-01-XX) SYMPTOM/CONDITION: Automatic transmission slips in reverse at mid throttle. PARTS REQUIRED: 1 52118761 Line Pressure Sleeve, Transmission Regulator Valve 1 52118763 Plug, Transmission Regulator Valve AR Reverse Drum AR Reverse Band AR Rear Servo Assembly REPAIR PROCEDURE: This bulletin involves replacing the regulator valve line pressure sleeve and plug. The reverse drum, reverse band, and rear servo assembly must also be inspected and replaced as necessary. 1. Check the transmission fluid level and correct as needed. 2. Disconnect the negative battery cable. 3. Disconnect the throttle valve cable and lever, the shift linkage, and the manual valve lever. 4. Raise the vehicle on a suitable hoist so that the transmission valvebody pan is accessible. 5. Remove the valvebody pan (use precaution when draining hot transmission fluid). 6. Remove the valvebody. 7. Visually inspect the reverse drum and the reverse band for signs of heat distress and or wear. If either are noted, the reverse drum, reverse band, and valve body must be replaced. The transmission must then be thoroughly cleaned including a cooling system flush. 8. Remove the two fasteners from the valve cover plate on the upper valvebody and remove the cover plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 211995A > Jan > 96 > A/T - Slips In Reverse At Mid Throttle > Page 2409 9. Remove the regulator valve line pressure sleeve and plug. Figure 1 NOTE: If the sleeve appears to have a red finish, the new plug and sleeve have already been installed and a problem exists elsewhere in the system. Refer to the appropriate transmission section for further diagnostics. 10. Install the new regulator valve line pressure sleeve (P/N 52118761) and plug (P/N 52118763) in the same position as previous parts were removed from. Figure 1 11. Install the cover and torque the fasteners to 35 in lbs (4 Nm). 12. Visually inspect the rear servo piston assembly for any signs of cracking or fatigue, replace as required. 13. Install the valvebody and torque the fasteners to 100 in lbs (11 Nm). 14. Install the valvebody pan and torque the fasteners to 13 ft. lbs (17 Nm). 15. Lower the vehicle. 16. Reconnect the manual valve lever, the throttle valve lever and cable, and shift linkage. Adjust the shift linkage and the throttle valve cable per the appropriate service manual procedures. 17. Connect the negative battery cable. 18. Fill the transmission with MS-7176 (Mopar P/N 4467721). 19. Check the fluid level with the parking brake on, the gear selector in neutral, and the engine on. Adjust the level as required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: **21-55-01-94 2.3 Hrs. 1996 (AB,AN,BR) (4x2 Models) Replace Line Pressure Valve, Regulator Valve Plug.** **21-55-01-95 3.1 Hrs 1996 (AB,AN,BR) (4x4 Models) Replace Line Pressure Valve, Regulator Valve Plug.** Optional Equipment: 21-00-01-60 0.2 Hrs 1996 (AB,AN,BR) (4x4 Models) Skid Plate Equipped FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse Technical Service Bulletin # 21-11-97A Date: 970905 A/T - Buzz Sound Shifting Into reverse NO: 21-11-97 Rev.A GROUP: Transmission DATE: Sep. 5, 1997 SUBJECT: Reverse Buzz (46RE) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-11-97 WITH AN EFFECTIVE DATE OF AUG. 15, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO THE REVERSE BAND ADJUSTMENT PROCEDURE. MODELS: 1996-1997 (AB) Ram Van/Wagon 1996 (AN) Dakota 1996-1997 (BR) Ram Truck SYMPTOM/CONDITION: Buzz sound when shifting into reverse. This condition may be more noticeable on a cold vehicle that has been parked outside overnight. DIAGNOSIS: Starting with a cold vehicle (parked outside overnight), start the engine and shift the transmission from park to reverse and from drive to reverse several times while listening for a buzz sound when in reverse. The buzz may be more noticeable with the windows down or from outside the cab. If the buzz occurs when in reverse, perform the Repair Procedure. PARTS REQUIRED: 1 04897877AA Package, Reverse Buzz 1 02464324 Gasket, Pan AR (Qts) 04798233 Fluid, ATF +2 Type 7176 AR (1) 03515996 Filter, fluid AR (1) 06030910 Seal, Reaction Pin REPAIR PROCEDURE: This bulletin involves removing the overdrive unit, propeller shafts, and (transfer case if applicable) and replacing the rear band adjusting lever, reaction lever and strut with high ratio components along with replacement of the regulator valve pressure plug and sleeve. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-15-05-96 2.7 Hrs. Optional Equipment: 21-15-05-60 4X4 Equipped BR 1.7 Hrs. 4X4 Equipped AN 1.5 Hrs. FAILURE CODE: P8 - New Part Propeller Shaft and Transfer Case (If Equipped) 1. Shift the transmission into park and the transfer case into neutral. 2. Record all radio presets and disconnect the negative battery cable. 3. Raise and support the vehicle on a hoist. 4. Remove the transfer case skid plate if so equipped. 5. Mark the front and rear propeller shafts and U-joints for alignment reference and remove the shafts. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2415 6. Disconnect the wires at the vehicle speed sensor. 7. Disconnect the vent hose and vacuum harness at the transfer case switch, if equipped. 8. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easier access. 9. Support transmission with a jack stand. 10. Remove the rear cross member. 11. Support the transfer case with a suitable jack (secure the transfer case to the jack with safety chains). 12. Remove nuts attaching transfer case to the transmission. 13. Move transfer case rearward until it is free of the transmission output shaft. 14. Lower the jack and move the transfer case from under the vehicle. Pan/Filter/Valve Body Removal 1. Remove the gear shift and throttle levers form shaft of valve body manual lever. 2. Disconnect wires at solenoid case connector. 3. Position a drain pan beneath the transmission oil pan. 4. Loosen the oil pan bolts to allow the transmission to drain into the drain pan. 5. While supporting the oil pan, remove all bolts and lower the oil pan away from the transmission. Drain the remaining fluid into the drain pan. 6. Remove the fluid filter from the valve body. 7. Remove the valve body to transmission case bolts. 8. Lower valve body enough to remove accumulator piston and springs. 9. Work manual lever shaft and electrical connector out of transmission case. 10. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. Overdrive Removal NOTE: THE OVERDRIVE UNIT MUST BE FULLY SUPPORTED DURING REMOVAL. THIS IS NECESSARY TO PREVENT DAMAGING THE INTERMEDIATE SHAFT. DO NOT ALLOW THE SHAFT TO SUPPORT THE ENTIRE WEIGHT OF THE OVERDRIVE UNIT. 1. Remove the bolts attaching the overdrive unit to the transmission. NOTE: USE CARE WHEN SEPARATING THE OVERDRIVE UNIT FROM THE TRANSMISSION TO PREVENT GASKET DAMAGE. 2. Carefully slide the overdrive unit off the intermediate shaft. Do not tilt unit during removal. Keep the unit as level as possible. 3. Insert alignment tool 6227-2 into the splines of planetary gear and overrunning clutch to prevent the splines from rotating out of alignment. NOTE: IF MISALIGNMENT OCCURS, THE OVERDRIVE UNIT WILL HAVE TO BE DISASSEMBLED IN ORDER TO RE-ALIGN THE SPLINES. 4. Remove and retain the overdrive piston thrust bearing and spacer. NOTE: THE BEARING MAY REMAIN ON THE PISTON OR IN THE CLUTCH HUB DURING REMOVAL. Reverse Band Levers and Strut Replacement 1. Loosen the locknut and unscrew the reverse band adjusting screw (but do not remove the screw). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2416 2. Using a small punch and hammer, tap the reverse band reaction pin out from the front until it can be removed. Remove the shaft so both levers can be removed (Figure 1). Discard the removed levers and strut. 3. Inspect the shaft "0" rings and replace them if necessary p/n 06030910. 4. Compress the rear servo piston enough to permit snap ring removal. 5. Remove the servo piston snap ring. Use caution when removing to prevent servo bore scratching. 6. Remove the rear servo retainer, spring, and piston assembly (Figure 2). 7. Measure the distance from the end of the rear servo piston plug to the face of the piston (Figure 3). Record this measurement for future use when adjusting the rear band. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2417 8. Re-install the rear servo retainer, spring, and piston into the transmission. Secure it with the snap ring. 9. Install the band adjusting screw (from old lever) and partially install the (new) band adjusting lever by pushing the reaction shaft through one flange of the lever p/n 04897877AA. 10. Using PETROLEUM JELLY, assemble the replacement strut and reaction lever p/n 04897877AA. 11. Install the assembled strut and reaction lever inside the adjusting lever and push the reaction pin completely through the assembly until it is flush with the back of the transmission case. NOTE: MAKE SURE THE STRUT IS INSTALLED CORRECTLY INTO THE LOW REVERSE BAND. TO CHECK INSTALLATION, APPLY THE ADJUSTING LEVER BY HAND AND NOTE THE MOVEMENT OF THE BAND. IF IT IS NOT INSTALLED CORRECTLY, LOOSEN THE ADJUSTING SCREW UNTIL THE STRUT CAN BE PUT IN PLACE WITHOUT DISASSEMBLING THE LEVERS. NOTE: DO NOT TIGHTEN THE ADJUSTING SCREW AT THIS POINT. Overdrive Installation 1. Inspect the gasket to make sure it was not damaged during removal. If damaged, refer to the service manual for replacement. 2. Install the thrust bearing and spacer in overdrive unit sliding hub. Use petroleum jelly to hold it in place. 3. Carefully slide the alignment tool 6227-2 out of the unit. 4. Raise the overdrive unit and carefully slide it straight onto the intermediate shaft. 5. Install the attaching bolts and tighten the bolts to 34 Nm (25 ft lbs) in a diagonal pattern. 6. Install the transmission mount and tighten to 41 Nm (30 ft lbs). 7. Connect speed sensors and speedometer wires. Reverse Band Adjustment 1. Remove the plug in the rear servo test port. 2. Based on the measurement taken in step 7 of REVERSE BAND LEVERS AND STRUT REPLACEMENT select the appropriate size drill bit from the table: 3. Insert the butt end of the appropriate drill bit into the test port 3 inches deep and centered beneath the servo plug. 4. With the bit properly located, tighten the reverse band adjusting screw to 8 Nm (72 in lbs) and back off the screw 2 1/4 turns. **5. Loosen the adjusting screw and repeat step 4. While holding the adjusting screw, tighten the adjusting screw lock nut to 34 Nm (25 ft lbs).** 6. Remove the drill bit and replace the rear servo test port plug. Pressure Plug and Sleeve Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 21-11-97A > Sep > 97 > A/T - Buzz Sound Shifting Into reverse > Page 2418 1. Without disassembling the valve body, remove the regulator valve cover hiding the pressure plug and sleeve (Figure 4). 2. Remove the existing pressure plug and sleeve and discard the old parts. Install the replacement parts from the kit. 3. Reinstall the regulator valve cover and tighten the screws. RE-Installation of Remaining Components 1. Place valve body manual lever in low (1 position) so ball on rod will be easier to install in sprag. 2. Position valve body in case and work end of park lock rod into and through pawl sprag. Move rod to check engagement. 3. Install accumulator piston and springs. The inner spring has a smaller diameter. 4. Swing valve body over piston and outer spring to hold it in place. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 5. Seat valve body in case and install the bolts. Alternately tighten each bolt to 11 Nm (100 in lbs). 6. Install the fluid filter. Replace as necessary p/n 03515996. 7. Install throttle and gearshift levers on valve body manual shaft. 8. Check and adjust front band if necessary. 9. Connect solenoid case connector wires. 10. Install the oil pan with a new gasket p/n 02464324. Tighten the pan bolts to 17 Nm (13 ft lbs). 11. If applicable, mount the transfer case on a jack and secure with chains. 12. Align transfer case and transmission shaft and install transfer case on transmission. Tighten the transfer case bolts to 35 Nm (26 ft lbs). 13. Connect the vent hose. 14. Connect indicator switch harness to transfer case, if necessary. Secure wire harness to clips on transfer case. 15. Align and connect propeller shafts. Tighten attaching bolts to 19 Nm (170 in lbs). 16. Lower vehicle. 17. Fill transmission with Mopar ATF +2, type 7176 fluid p/n 04798233. 18. Reconnect the negative battery cable and set radio presets recorded in step 2 of the first procedure. 19. Adjust the gearshift linkage and throttle valve cable if necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 211995A > Jan > 96 > A/T - Slips In Reverse At Mid Throttle Band: All Technical Service Bulletins A/T - Slips In Reverse At Mid Throttle NO: 21-19-95 Rev. A GROUP: Transmission DATE: Jan 5, 1996 SUBJECT: Automatic Transmission Slips In Reverse At Mid Throttle NOTE: This bulletin supersedes Technical Service Bulletin 21-19-95 dated November 24, 1995 which should be removed from your files. The labor operation number coverage statements for both 4X2 and 4X4 vehicles has been revised to fit the repair and is marked with **asterisks** MODELS: 1996 (AB) Ram Van/wagon 1996 (AN) Dakota 1996 (BR) Ram Truck NOTE: This bulletin applies to vehicles built with the 36RH and 46RE transmissions only built prior to December 1, 1995 (MDH 12-01-XX) SYMPTOM/CONDITION: Automatic transmission slips in reverse at mid throttle. PARTS REQUIRED: 1 52118761 Line Pressure Sleeve, Transmission Regulator Valve 1 52118763 Plug, Transmission Regulator Valve AR Reverse Drum AR Reverse Band AR Rear Servo Assembly REPAIR PROCEDURE: This bulletin involves replacing the regulator valve line pressure sleeve and plug. The reverse drum, reverse band, and rear servo assembly must also be inspected and replaced as necessary. 1. Check the transmission fluid level and correct as needed. 2. Disconnect the negative battery cable. 3. Disconnect the throttle valve cable and lever, the shift linkage, and the manual valve lever. 4. Raise the vehicle on a suitable hoist so that the transmission valvebody pan is accessible. 5. Remove the valvebody pan (use precaution when draining hot transmission fluid). 6. Remove the valvebody. 7. Visually inspect the reverse drum and the reverse band for signs of heat distress and or wear. If either are noted, the reverse drum, reverse band, and valve body must be replaced. The transmission must then be thoroughly cleaned including a cooling system flush. 8. Remove the two fasteners from the valve cover plate on the upper valvebody and remove the cover plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 211995A > Jan > 96 > A/T - Slips In Reverse At Mid Throttle > Page 2423 9. Remove the regulator valve line pressure sleeve and plug. Figure 1 NOTE: If the sleeve appears to have a red finish, the new plug and sleeve have already been installed and a problem exists elsewhere in the system. Refer to the appropriate transmission section for further diagnostics. 10. Install the new regulator valve line pressure sleeve (P/N 52118761) and plug (P/N 52118763) in the same position as previous parts were removed from. Figure 1 11. Install the cover and torque the fasteners to 35 in lbs (4 Nm). 12. Visually inspect the rear servo piston assembly for any signs of cracking or fatigue, replace as required. 13. Install the valvebody and torque the fasteners to 100 in lbs (11 Nm). 14. Install the valvebody pan and torque the fasteners to 13 ft. lbs (17 Nm). 15. Lower the vehicle. 16. Reconnect the manual valve lever, the throttle valve lever and cable, and shift linkage. Adjust the shift linkage and the throttle valve cable per the appropriate service manual procedures. 17. Connect the negative battery cable. 18. Fill the transmission with MS-7176 (Mopar P/N 4467721). 19. Check the fluid level with the parking brake on, the gear selector in neutral, and the engine on. Adjust the level as required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: **21-55-01-94 2.3 Hrs. 1996 (AB,AN,BR) (4x2 Models) Replace Line Pressure Valve, Regulator Valve Plug.** **21-55-01-95 3.1 Hrs 1996 (AB,AN,BR) (4x4 Models) Replace Line Pressure Valve, Regulator Valve Plug.** Optional Equipment: 21-00-01-60 0.2 Hrs 1996 (AB,AN,BR) (4x4 Models) Skid Plate Equipped FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown Band: Specifications With 3 speed trans 72 in.lb Then back off 2 1/4 turns. With 42RH trans 72 in.lb Then back off 2 1/4 turns. With 46RH trans 72 in.lb Then back off 2 7/8 turns. With 47RH trans 72 in.lb Then back off 1 7/8 turns. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown > Page 2426 Band: Specifications With 3 speed trans 72 in.lb Then back off 4 turns. With 42RH trans 72 in.lb Then back off 4 turns. With 46RH trans 72 in.lb Then back off 2 turns. With 47RH trans 72 in.lb Then back off 3 turns. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 2427 Band: Adjustments FRONT BAND ADJUSTMENT The front (kickdown) band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers. 1. Raise vehicle. Front Band Adjustment Screw Location 2. Loosen band adjusting screw locknut. Then back locknut off 3-5 turns. Be sure adjusting screw turns freely in case. Apply lubricant to screw threads if necessary. 3. Tighten band adjusting screw to 8 Nm (72 inch lbs.) torque with Inch Pound Torque Wrench C-3380-A, a 3-in. extension and 5/16 socket. Band Adjustment Adapter Tool CAUTION: If Adapter C-3705 is needed to reach the adjusting screw, tighten the screw to only 5 Nm (47-50 inch lbs.) torque. 42RE Transmission Back off front band adjusting screw 3 5/8 turns. - Hold adjuster screw in position and tighten locknut to 41 Nm (30 ft. lbs.) torque. 4. Lower vehicle. REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw. 1. Raise vehicle. 2. Remove transmission oil pan and drain fluid. 3. Loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 2428 Rear Band Adjustment Screw Location 4. Tighten adjusting screw to 8 Nm (72 inch lbs.) torque. 42RE Transmission Back off adjusting screw 4 turns. - Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque. 5. Position new gasket on oil pan and install pan on transmission. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 6. Lower vehicle and refill transmission with Mopar (R) ATF Plus 4, Type 7176 fluid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations > Page 2432 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2441 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2442 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2448 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2449 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2450 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair On some models, it is necessary to unload both torsion bars and drop one side of torsion bar crossmember to provide clearance for extension housing removal. 1. Mark parts for reassembly and remove propeller shaft. 2. Remove speedometer pinion and adapter assembly, then drain about two quarts of fluid from transmission. 3. Remove extension housing to crossmember bolts, then raise transmission with jack and remove crossmember. 4. Remove extension housing to transmission bolts. On console shift models, remove torque shaft lower bracket to extension housing bolts. NOTE: In the following step, the gearshift must be in "low", therefore positioning the parking lock control rod rearward so it can be disengaged or engaged with the parking lock sprag. Fig. 17 Extension Snap Ring Replacement 5. Remove two screws, plate and gasket from bottom of extension housing mounting pad, then spread snap ring from output shaft bearing, Fig. 17, and carefully tap extension housing off output shaft bearing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Page 2454 Parking Lock Components 6. Slide extension housing off shaft to remove parking sprag and spring, then remove snap ring and slide reaction plug and pin assembly out of housing, Fig. 18. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2459 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2460 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2461 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2462 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 2463 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Dry Refill Capacity 47RH ..................................................................................................................... ........................................................ 14.6L (15.4 Qt) Initial Refill Capacity 46RH ................................ .............................................................................................................................................. 4.9L (5.7 Qt) Initial Refill Capacity All others ...................................................................................................... ................................................................. 4.4L (5.2 Qt) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2466 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Automatic Transmission Fluid Mopar ATF Plus 4, Type 9602 automatic transmission fluid is the recommended fluid for Chrysler automatic transmissions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure Technical Service Bulletin # 211596 Date: 961108 A/T - Quick Connect Removal & Reconnect Procedure NO: 21-15-96 GROUP: Transmissions DATE: Nov. 8, 1996 SUBJECT: Quick Connect Removal & Reconnect Procedure NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-95, DATED MAR. 31, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 BOUND COPY OF TECHNICAL SERVICE BULLETINS (PUBLICATION NO. 81-699-96084). THIS BULLETIN INCLUDES THE ADDITION OF THE 1996 AND 1997 MODEL YEARS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - **1997** (AB) Ram Van/Wagon 1995 - **1997** (AN) Dakota 1995 - **1997** (BR) Ram Truck 1995 - **1996** (XJ) Cherokee 1995 (YJ) Wrangler 1995 - **1997** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION, WITH 3/8" COOLER LINE (ALL EXCEPT BR DIESEL & V-10) BUILT AFTER 1/20/95 (MDH 01-20-XX), AND WITH 1/2" COOLER LINE (BR DIESEL & V-10) BUILT AFTER 3/20/95 (MDH 03-20-95). DISCUSSION: Automatic transmission equipped vehicles now include quick connector fittings in the transmission cooler lines. If the transmission requires service, the connectors can be disconnected using either of the following two procedures. Proper reconnect procedures are also provided. **NOTE: SOME 1997 VEHICLES ARE NOT EQUIPPED WITH EXTERNAL RETAINER TABS. THESE VEHICLES MUST USE THE TOOL REMOVAL PROCEDURE TO DISCONNECT TRANSMISSION COOLER LINES.** POLICY: Information Only Removal Procedure This bulletin outlines the two methods of disconnecting the quick connectors on automatic transmission cooler lines, and provides the proper reconnect procedures. 1. Use a rag or soft brush to wipe the external surface of the connector and male line to remove loose dirt and road salt. Twist connector around the line or flush the joint with a mild soap penetrant such as Mopar General Purpose Lube MP-50 (P/N 4549626), to remove stubborn crusted contaminants. 2. Use an air nozzle to blow out accumulated dirt and road salt from the retainer area of the connector. Hand Removal Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 2471 1. Holding the line as shown, grasp connector body with fingers touching the retainer tabs (Figure 1). 2. Push line into connector until line stops (Figure 2). 3. Squeeze retainer tabs together until both tabs contact line (Figure 3). 4. Pull line out of the connector with other hand while retainer tabs are squeezed together (Figure 4). Tool Removal Procedure 1. Select the proper tool. For vehicles equipped with the 5.9L Cummins Diesel or the 8.0L gas engine (1/2" cooler lines), use Miller Special Tool 6931. All other vehicles use a 3/8" cooler line and require Miller Special Tool 6935. 2. Unlock the small tab on side of tool and open (Figure 5). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 2472 3. Wrap tool around line with smooth round end facing the connector (Figure 6). 4. Close removal tool and lock tab. Push removal tool up to connector (Figure 7). 5. Push removal tool into connector. Tool will push out retainer legs, pull connector over line bead (Figure 8). 6. Pull line connector while holding onto line with one hand and the connector with the other (Figure 9). Reconnect Procedure 1. After performing the service that required the line to be disconnected, wipe the line end with a clean rag. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 2473 2. Check the line surfaces for burrs on existing or replacement parts. 3. Apply a coating of clean transmission fluid over the entire male line end surface up to the bead. 4. Push the line into the connector until the retainer seats and a click is heard. Pull back on the line to ensure that the connector is locked in place (15-30 lbs.). Do not rely only on the audible click to confirm that a secure connection has been made. 5. Start the engine and check the connector for fluid leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2482 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2488 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair Fluid Pump: Service and Repair REMOVING OIL PUMP AND REACTION SHAFT SUPPORT 1. Tighten front band adjusting screw until band is tight on front clutch retainer. This prevents retainer from coming out with pump and causing unnecessary damage to clutch components. 2. Remove oil pump bolts. 3. Remove oil pump and reaction shaft support assembly with two slide hammer tools C-3752 (Fig. 3). Thread slide hammers into threaded holes in pump body flange. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm Governor: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm > Page 2500 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Governor: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2506 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 2507 Governor: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 2508 Governor: Service and Repair REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding pressure solenoid retainer to governor body. 5. Separate solenoid retainer from governor. 6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 2509 8. Separate governor body from valve body. 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. 11. Pull pressure sensor from governor body. NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. INSTALLATION 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 2514 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 2525 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 2529 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 2530 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2539 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2545 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2555 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2556 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2562 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2563 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2564 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2568 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2569 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair 1. Mark propeller shaft to aid in reassembly and remove propeller shaft being careful not to scratch or nick surface on sliding spline yoke. 2. Remove transmission flange or brake drum, if equipped. 3. Using a screwdriver and hammer, drive between extension housing and seal and remove seal. 4. Position new seal and drive it into extension housing using suitable tool. 5. Carefully install yoke into housing, then align marks made at removal and install propeller shaft. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations > Page 2577 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2586 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2592 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2596 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2597 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2601 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 2606 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 2607 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2611 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair Shift Interlock Cable: Service and Repair 1. Shift transmission into Park, then place ignition switch in Accessory position. Fig. 8 Park Interlock Cable 2. Remove shift lever bezel and console screws, then raise bezel and console to access park interlock cable, Fig. 8. 3. Pull cable lock button up to release cable, then pull cable forward. Release cable and press cable lock button down until it snaps in place. 4. Check cable adjustment. With shift lever in Park, ensure ignition switch rotates freely from Off to Lock and does not turn in any other position. 5. Verify brake/transmission interlock operation as follows: 6. Turn ignition switch to On position, then press and hold brake pedal down. 7. Pedal must travel at least 1/2 inch. 8. Press shift lever handle button in, then verify shift lever can be moved out of Park. 9. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Adjustments Shift Linkage: Adjustments Fig. 14 Gearshift Control Linkage 1. Loosen adjustable rod swivel lock bolt, Fig. 14. 2. Place selector lever in Park and move shift control lever on transmission all the way to the rear (in Park detent). 3. Tighten lock bolt to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments CHECKING THROTTLE CABLE ADJUSTMENT 1. Turn ignition key to OFF position. 2. Remove air cleaner on gas engines. Throttle Valve Cable Attachment 3. Verify that lever on throttle body is at curb idle position. Then verify that transmission throttle lever is also at idle position. 4. Slide cable off attachment stud on throttle body. Throttle Valve Cable Adjustment 5. Compare position of cable end to attachment stud on throttle body lever: a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 in.) in either direction. b. If cable end and attachment stud are mis- aligned (off center), cable will have to be adjusted as described in following adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. a. If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position. 2. Remove air cleaner. 3. Disconnect cable end from attachment stud on control lever. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Locate cable lock button. Button is part of cable retainer at engine end of cable. 6. Press cable lock button inward to release cable. Lock button only has to move about 2 mm (0.070 in.) to release cable in adjuster head. 7. Center cable end on attachment stud to within 1 mm (0.039 in.) and release lock button. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Page 2628 8. Check cable adjustment. Be sure transmission throttle lever and lever on throttle body, move simultaneously and as described in cable adjustment checking procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2632 Torque Converter Clutch Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 2636 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 2637 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2646 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2647 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2648 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2649 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2650 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2651 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures Technical Service Bulletin # 21-06-97A Date: 971219 A/T - Overdrive Unavailable in Cold Temperatures NO: 21-06-97 Rev. A GROUP: Transmission DATE: Dec. 19, 1997 SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS. MODELS: 1996 - **1998** (AB) Ram Van/Wagon 1996 (AN) Dakota 1996 - **1998** (BRIBE) Ram Truck 1996 - **1998** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION. SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy. DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures. NOTE: THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2657 PARTS/EQUIPMENT REQUIRED: **1 04798668 Kit, By-Pass V-10 Applications** 1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents) AR(1) 04318044 Thread Sealant 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2658 WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit, selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes for 1996 models only), and using the DRB III to selectively turn off the overdrive inhibitor feature for all applications. NOTE: IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. NOTE: EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS MAY TAKE SEVERAL MINUTES. Bypass Kit Installation 1. Record all radio pre-sets and disconnect the negative battery cable. 2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter. 3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation. 4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal. 5. Disconnect the pressure and return lines from the transmission housing fittings. 6. Remove and discard the fittings from the transmission housing. 7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1). 8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). 9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF. 10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward. 11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter. NOTE: THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER. CAUTION: IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE. 12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting. 13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2659 14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line. CAUTION: AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION. 15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes. 16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.). 17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2660 application. 18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block. 19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block. NOTE: DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS. NOTE: ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY. 20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it. 21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system. 22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line. 24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line. 25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing. 27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly. 28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing. CAUTION: WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM. 29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line. 30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line. 31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1). 32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing. 33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line. 35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system. 36. If applicable, connect the wire harness to the temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2661 37. Lower the vehicle. 38. Re-connect the negative battery cable and reset the radio stations recorded in step one. 39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual. 40. Raise the vehicle and check for leaks (idle in Neutral). Flash Programming (1996 Models) NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 2662 Programming Cold Overdrive Feature (All Applications) Using the DRB III, use the following procedures to program the overdrive cutoff feature. 1. Connect the DRB III (Scan Tool) to the vehicle and power it up. 2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU. 4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU. 5. The module ID screen will appear, press enter to move to next menu. 6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS. 7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE. 8. Follow the steps presented on the DRB III which will prompt you through the feature selection. 9. When the password is asked for use: 84362172. 10. Follow the remaining prompts for overdrive feature verification. NOTE: IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED. Policy/Time Allowance/Failure Code POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs. 21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 210797 > Mar > 97 > A/T Cooler - Reverse Flush With Bypass Kit Installed Transmission Cooler: All Technical Service Bulletins A/T Cooler - Reverse Flush With Bypass Kit Installed NO: 21-07-97 GROUP: Transmission DATE: Mar. 21, 1997 SUBJECT: Transmission Cooler Reverse Flushing with Cooler Bypass Kit Installed MODELS: 1989-1997 (AB) Ram Van/Wagon 1989-1993 (AD) Ram Pickup 1989 - 1996 (AN) Dakota 1994 - 1997 (BR) Ram Truck 1993-1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION WITH A COOLER BYPASS KIT INSTALLATION. DISCUSSION: Whenever reverse flushing is necessary, the bypass valve assembly must be removed from the system prior to performing the procedure. Failure to remove the bypass valve may plug the valves orifice and drainback valve. Plugging of this valve may result in transmission failure. In addition to the above recommendations, the valve and adaptor may require replacement if a transmission failure causes an excess amount of debris to be suspended in the transmission fluid. The bypass valve p/n 04798633 and adaptor p/n 04798634 can be ordered separately from the kit. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 210797 > Mar > 97 > A/T Cooler - Reverse Flush With Bypass Kit Installed Transmission Cooler: All Technical Service Bulletins A/T Cooler - Reverse Flush With Bypass Kit Installed NO: 21-07-97 GROUP: Transmission DATE: Mar. 21, 1997 SUBJECT: Transmission Cooler Reverse Flushing with Cooler Bypass Kit Installed MODELS: 1989-1997 (AB) Ram Van/Wagon 1989-1993 (AD) Ram Pickup 1989 - 1996 (AN) Dakota 1994 - 1997 (BR) Ram Truck 1993-1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION WITH A COOLER BYPASS KIT INSTALLATION. DISCUSSION: Whenever reverse flushing is necessary, the bypass valve assembly must be removed from the system prior to performing the procedure. Failure to remove the bypass valve may plug the valves orifice and drainback valve. Plugging of this valve may result in transmission failure. In addition to the above recommendations, the valve and adaptor may require replacement if a transmission failure causes an excess amount of debris to be suspended in the transmission fluid. The bypass valve p/n 04798633 and adaptor p/n 04798634 can be ordered separately from the kit. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2675 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 2683 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 2684 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2688 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations Valve Body: Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 2692 Transmission Solenoids Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 2693 Valve Body: Description and Operation CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module (PCM) on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit T33 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 splices to circuit T35 which connects to the sensor. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > Throttle Pressure Valve Body: Adjustments Throttle Pressure Throttle pressures cannot be tested accurately; therefore, the adjustment should be measured if a malfunction is evident. 1. Remove valve body assembly. 2. Loosen throttle lever stop screw locknut and back off approximately five turns. Fig. 7 Throttle Pressure Adjustment 3. Insert a suitable tool, Fig. 7, between throttle lever cam and kickdown valve. 4. Push in on tool, compress kickdown valve against its spring so throttle valve is completely bottomed inside valve body. 5. As force is being exerted to compress spring, tighten throttle lever stop screw against throttle lever tang with throttle lever cam touching tool and throttle valve bottomed. Be sure adjustment is made with spring fully compressed and valve bottomed in valve body. 6. Remove tool and tighten stop screw locknut securely. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Adjustments > Throttle Pressure > Page 2696 Valve Body: Adjustments Line Pressure An incorrect throttle pressure setting will cause incorrect line pressure readings even though line pressure adjustment is correct. Always inspect and correct throttle pressure adjustment before adjusting line pressure. Fig. 13 Measuring Spring Retainer Location NOTE: Before adjusting line pressure, measure distance between manual valve (valve in No. 1 low position) and line pressure adjusting screw, Fig. 13. This measurement must be 15/16 inch. Correct by loosening spring retainer screws and repositioning spring retainer. The regulator valve may cock and may hang up in its bore if spring retainer is out of position. If line pressure is not correct, it may be necessary to remove valve body assembly to perform the adjustment. The approximate adjustment is 1 5/16 inch measured from valve body to inner edge of adjusting nut. However, due to manufacturing tolerances, the adjustment can be varied to obtain specified line pressure. The adjusting screw may be turned with an Allen wrench. One complete turn of the adjusting screw changes closed throttle line pressure approximately 1 2/3 psi. Turning adjusting screw counterclockwise increases pressure, and clockwise decreases pressure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation NOTES: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. The only replaceable valve body components are: - Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter - Pressure adjusting screw bracket - Governor pressure solenoid. - Governor pressure sensor. - Converter clutch/overdrive solenoid assembly and harness (includes sump temperature thermistor). - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. 4. Disconnect wires at solenoid case connector. 5. Position drain pan under transmission oil pan. 6. Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts attaching valve body to transmission. 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft and electrical connector out of transmission case. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2699 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. INSTALLATION 1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. 2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket. 3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. 13. Install throttle and gearshift levers on valve body manual lever shaft. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2700 14. Check and adjust front and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve cables, if necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2701 Valve Body: Service and Repair Disassembly Lower Housing Disassembly 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. Main Component Body CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2702 Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2703 Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2704 Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2705 Boost Valve Cover Location 13. Remove boost valve cover. Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2706 Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2707 Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2708 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2709 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2710 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2711 Upperhousing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. Upper Housing Disassembly Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2712 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2713 Upper Housing Control Valve Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. 3-4 Accumulator 1. Remove end plate from housing. 2. Remove piston spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2714 Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2715 Valve Body: Service and Repair Cleaning and Inspection Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2716 Upper Housing Valves, Plugs, Springs And Brackets Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2717 CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2718 Valve Body: Service and Repair Assembly Assembly Precaution CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. NOTE: Follow assembly steps in order shown for proper valve body assembly. Boost Valve and Brace Assembly Boost Valve Tube 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2719 Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. Governor Body, Sensor and Solenoid Assembly 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2720 Governor Body And Gasket 6. Position governor body gasket on transfer plate. Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Lower Housing Disassembly Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2721 Lower Housing Shift Valves And Springs 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. Transfer Plate Assembly Rear Clutch And Rear Servo Sheck Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2722 Seperator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. Upper and Lower Housing Assembly Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2723 Installing Transfer Plate On Upper Housing 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. ECE Check Ball 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2724 Installing Lower Housing On Transfer Plate And Upper Housing 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Upper Housing Valve and Plug Assembly Shuttle And Boost Valve Components Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2725 Upper Housing Control Valve Locations Upper Housing Shift Valve And Pressure Plug Locations Refer to figures to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2726 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. Valve Body Final Assembly and Adjustment 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2727 Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 3-4 Accumulator Assembly Installation Converter Clutch And 3-4 Shift Valve Springs 1. Position converter clutch valve and 3-4 shift valve springs in housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2728 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Reassembly Accumulator Housing Components 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. 3-4 Accumulator 1 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2729 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2730 Valve Body: Service and Repair Removal and Installation NOTES: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. The only replaceable valve body components are: - Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter - Pressure adjusting screw bracket - Governor pressure solenoid. - Governor pressure sensor. - Converter clutch/overdrive solenoid assembly and harness (includes sump temperature thermistor). - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. 4. Disconnect wires at solenoid case connector. 5. Position drain pan under transmission oil pan. 6. Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts attaching valve body to transmission. 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft and electrical connector out of transmission case. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2731 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. INSTALLATION 1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. 2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2732 3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. 13. Install throttle and gearshift levers on valve body manual lever shaft. 14. Check and adjust front and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve cables, if necessary. Lower Housing Disassembly 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2733 Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. Main Component Body CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2734 Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2735 Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2736 Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Boost Valve Cover Location 13. Remove boost valve cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2737 Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2738 Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2739 Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2740 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2741 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2742 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2743 Upperhousing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. Upper Housing Disassembly Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2744 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2745 Upper Housing Control Valve Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. 3-4 Accumulator 1. Remove end plate from housing. 2. Remove piston spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2746 Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. Cleaning and Inspection Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2747 Upper Housing Valves, Plugs, Springs And Brackets Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2748 CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Assembly Precaution CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. NOTE: Follow assembly steps in order shown for proper valve body assembly. Boost Valve and Brace Assembly Boost Valve Tube Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2749 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. Governor Body, Sensor and Solenoid Assembly 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2750 Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Governor Body And Gasket 6. Position governor body gasket on transfer plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2751 Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Lower Housing Disassembly Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2752 Lower Housing Shift Valves And Springs 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. Transfer Plate Assembly Rear Clutch And Rear Servo Sheck Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2753 Seperator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. Upper and Lower Housing Assembly Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2754 Installing Transfer Plate On Upper Housing 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. ECE Check Ball 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2755 Installing Lower Housing On Transfer Plate And Upper Housing 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Upper Housing Valve and Plug Assembly Shuttle And Boost Valve Components Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2756 Upper Housing Control Valve Locations Upper Housing Shift Valve And Pressure Plug Locations Refer to figures to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2757 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. Valve Body Final Assembly and Adjustment 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2758 Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 3-4 Accumulator Assembly Installation Converter Clutch And 3-4 Shift Valve Springs 1. Position converter clutch valve and 3-4 shift valve springs in housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2759 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Reassembly Accumulator Housing Components 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. 3-4 Accumulator 1 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2760 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. Lock-Up Module Replacement Fig. 15 Lock-up Module Disassembly 1. Remove end cover, Fig. 15. 2. Remove lock-up spring and valve. 3. Remove fail-safe valve and spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 2761 4. Tag these springs as they are removed for reassembly. Valve Body Replacement 1. Drain transmission and remove oil pan. 2. Loosen clamp bolts and remove throttle and/or gear selector levers from manual lever. 3. Remove neutral safety switch. 4. Place a drain pan under transmission and remove the ten valve body to transmission bolts. Hold valve body in place while removing bolts. 5. Carefully lower valve body. Pull valve body forward to disengage parking control rod. It may be necessary to rotate output shaft to permit parking control rod to clear sprag. 6. Remove accumulator piston and spring from transmission case. Inspect piston for nicks, scores and wear. Inspect spring for distortion. Inspect rings for freedom in piston grooves and wear or breakage. Replace parts as necessary. CAUTION: Never clamp any portion of the valve body or transfer plate in a vise. Any slight distortion of the aluminum body or the transfer plate will result in sticking valves, excessive leakage or both. When removing or installing valves or plugs, slide them in or out carefully; do not use force. 42RE/42RH/46RH/47RH 4-Speed 1. Raise and support vehicle with transmission in Neutral position. 2. Drain fluid and remove oil pan. 3. Loosen clamp bolts, then remove throttle and manual valve levers from manual lever shaft. 4. Remove neutral switch, then filter. 5. Disconnect lock-up solenoid electrical connector, then push connector through case. 6. Remove valve body attaching screws, then lower valve body enough to remove accumulator piston and piston springs. 7. Disengage park rod by pushing valve body forward. 8. Remove manual lever shaft and solenoid connector from case. Lower valve body, rotate it away from case, then pull park rod out of sprag and remove valve body. 9. Reverse procedure to install, noting the following: a. Ensure neutral switch is not installed prior to valve body, as valve body cannot be installed when switch is in place. b. Place valve body manual lever in low position when installing park rod into sprag. c. Tighten valve body attaching bolts and oil pan bolts to specifications. d. Fill transmission with MOPAR ATF+4 Type 9602 , or equivalent. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Service and Repair Clutch Linkage: Service and Repair 1. Raise and support vehicle. 2. Remove slave cylinder attaching nuts, then the slave cylinder and clip from housing. 3. Remove hydraulic fluid line from body clips, then lower vehicle. 4. Carefully remove retaining clip from clutch master cylinder mounting bracket, disconnect clutch master cylinder pushrod from clutch pedal. 5. Remove screws attaching clutch reservoir to dash panel, then pull clutch master cylinder rubber seal from dash panel. 6. Rotate clutch master cylinder 45° counterclockwise to unlock it, then remove cylinder from dash panel. 7. Remove clutch hydraulic linkage from vehicle. 8. Reverse procedure to install. Tighten screws and nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair It is not necessary to remove complete axle for routine service. 1. Raise and support vehicle, then remove skid plate. 2. Remove CV drive shaft as outlined under Drive Axles.../ Axle Shaft Assembly, Constant Velocity Type/ CV Joint Service. 3. Remove front driveshaft. Fig. 1 Front Drive Axle Mounts 4. Support axle housing assembly with suitable jack, then remove attaching bolts and lower axle housing assembly from vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 2773 5. Reverse procedure to install. Drift pin will be helpful for aligning bolts holes. Tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front 4WD 7 1/4" ................................................................................................................................. .................................................................. 1.4L (3.0 Pints) Dana 44 ................................................... ...................................................................................................................................................... 2.7L (5.6 Pints) Dana 60 .............................................................................................................................. ........................................................................... 3.0L (6.3 Pints) Rear 7 1/4" ..................................... .............................................................................................................................................................. .......... 1.4L (3.0 Pints) 8 1/4" ............................................................................................................... .............................................................................................. 2.1L (4.4 Pints) 9 1/4" ........................... .............................................................................................................................................................. .................... 2.2L (4.7 Pints) Dana 60 ................................................................................................. ........................................................................................................ 3.0L (6.3 Pints) Dana axles, lubricant level in axle must be 1/2 - 1" below fill plug opening. All with limited slip, add one container of MOPAR Trac-Loc additive. Rear Dana axles with limited slip include 0.2 L (0.4 pts) friction modifier additive ex Dana 80 4WD application include 0.3 L (0.6 pts) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2778 Fluid - Differential: Fluid Type Specifications Rear Differential Fluid Type 7 1/4 ..................................................................................................................................................... ............................................................. SAE 80W-90 8 1/4 inch Axle ..................................................................................................................................... ............................................................ SAE 80W-90 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair Pinion Gear: Service and Repair NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer. Pinion Yoke Removal 5. Using Remover C-452, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut onto pinion to protect the threads. Remove Pinion Gear 7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing. 10. Remove the front pinion bearing cup with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 2782 Rear Bearing Cup Removal 11. Remove the rear bearing cup from housing. Use Remover C-4309 and Handle C-4171 for the 9 1/4 axle. Collapsible Spacer 12. Remove the collapsible preload spacer. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 2783 Rear Bearing Removal 13. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-29337. Place 4 adapter blocks so they do not damage the bearing cage. 14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Pinion Rear Bearing Cup Installation 2. Install the pinion rear bearing cup with Installer C-4310 and Driver Handle C-4171. 3. Ensure cup is correctly seated. 4. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 2784 Pinion Front Bearing Cup Installation 5. Install the pinion front bearing cup with Installer D-129 and Handle C-4171. 6. Install pinion front bearing, and oil slinger, if equipped. 7. Apply a light coating of gear lubricant on the lip of pinion seal. 8. Install seal with Installer C-3860-A and Handle C-4171. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. 9. Place the proper thickness depth shim on the pinion gear. Shaft Rear Bearing Installation 10. Install the rear bearing and slinger, if equipped, on the pinion gear with Installer C-3095. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 2785 Collapsible Preload Spacer 11. Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing. 12. Install pinion gear in housing. 13. Install yoke with Installer C-3718 and Yoke Holder 6719. 14. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed. 15. Tighten the nut to 285 Nm (210 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 16. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up. Check Pinion Gear Rotating Torque 17. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 18. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 19. Install propeller shaft. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 2786 20. Install differential in housing. FINAL ASSEMBLY Typical Housing Cover With Sealant 1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of MOPAR Silicone Rubber Sealant, or equivalent, on the housing cover. Install the housing cover within 5 minutes after applying the sealant. 2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for the gear lubricant requirements. 4. Install the fill hole plug. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair Axle Bearing: Service and Repair 1. Remove axle shaft as outlined under Drive Axles.../ Service and Repair/ Front Axle Shaft Replacement. Fig. 8 Axle Shaft, Seal & Bearing 2. Pry off seal, then remove bearing with bearing removal tool No. C-4167 and slide hammer tool No. C-637, or equivalents. 3. Reverse procedure to install, noting the following: a. Install bearing with installation tool No. C-4198 and handle tool No. C-4171, or equivalents. b. Do not use seal to position or set bearing. c. Install new seal with installation tool No. C-4203 and handle tool No. C-4171, or equivalents. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Service Axle Shaft: Service and Repair Front Axle Service Left Side 1. Raise and support vehicle, then remove CV shaft from axle flange as outlined under Constant Velocity Joint/ Service and Repair/ CV Joint Replacement. Fig. 2 Front Drive Axle Fig. 3 Front Drive Axle Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Service > Page 2796 2. Loosen housing cover bolts and drain lubricant, then remove cover. Fig. 4 Differential Pinion Shaft Lockpin 3. Rotate differential case until pinion shaft lock screw is accessible, then remove lock screw and pinion shaft. Fig. 5 Axle Shaft C-lock 4. Push axle shaft in and remove C-clip lock, then remove shaft being careful not to damage bearing which remains in tube. 5. Reverse procedure to install using Loctite on lock screw. Tighten bolts, nuts and screws to specifications. Right Side 1. Raise and support vehicle, then remove CV shaft from axle flange as outlined under Constant Velocity Joint/ Service and Repair/ CV Joint Replacement. 2. Remove shock absorber and remove torsion bar tension by turning adjustment bolt counterclockwise. Count number of turns for assembly. 3. Remove lower ball joint cotter pin and nut, then separate joint from knuckle with ball joint removal tool No. C-3564A, or equivalent. 4. Loosen housing cover bolts and drain lubricant, then remove cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Service > Page 2797 Fig. 4 Differential Pinion Shaft Lockpin 5. Rotate differential case until pinion shaft lock screw is accessible, then remove lock screw and pinion shaft. Fig. 5 Axle Shaft C-lock 6. Push axle shaft in and remove C-clip lock, then remove shaft being careful not to damage bearing which remains in tube. 7. Lift knuckle and upper control arm and remove axle shaft. Be careful not to damage bearing which remains in tube. 8. Reverse procedure to install using Loctite on lock screw. Tighten bolts, nuts and screws to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Service > Page 2798 Axle Shaft: Service and Repair Rear Halfshaft Replacement Both rear wheels must be free to rotate off ground when working on rear axle. Do not rotate axle shaft in locking differential models unless both axles are in place. Rotating with only one axle in place can cause side gears/splines to mis-align. 1. Raise and support vehicle, then remove wheel and brake drum. 2. Clean area around housing cover, then loosen housing cover and allow lubricant to drain. Remove cover. Fig. 3 Differential Pinion Shaft Lockpin Removal 3. Turn differential case until pinion shaft lock screw is accessible, then remove lock screw and pinion shaft. Fig. 4 C-lock Washer Removal 4. Push axle shaft in and remove C-clip lock from axle shaft, then pull axle shaft from housing being careful not to damage axle shaft bearing. NOTE: Inspect axle shaft bearing surfaces. If there is brinnelling, spalling or pitting shaft and bearing should be replaced. Normal bearing contact on shaft should be dull gray and may appear lightly dented. 5. Pry off axle shaft seal, then remove axle shaft bearing using bearing removal tool No. C-4167 and slide hammer tool No. C-637, or equivalents. NOTE: Remove any burrs that may be present in housing bearing shoulder, as bearing could become cocked during installation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Service > Page 2799 6. Using suitable tools, install bearing, making sure it does not become cocked. Drive bearing until it bottoms against shoulder. CAUTION: Do not use seal to position or bottom bearing as this will damage seal. 7. Reverse procedure to install, noting the following: a. Use bearing installer tool No. C-4198 and handle tool No. C-4171, or equivalents, to position and seat bearing in tube. Ensure bearing is not cocked and is firmly seated against tube shoulder. NOTE: Do no use new shaft seal to position or seat bearing in bore. b. Use seal installer tool No. C-4203 and handle tool No. C-4171, or equivalents, to install seal. c. Use Loctite on pinion gear lock screw and tighten to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair Constant Velocity Joint: Service and Repair 1. Remove cotter pin, lock nut and spring washer from stub axle, then loosen hub and lug nuts with vehicle on ground and brakes applied. 2. Raise and support vehicle, then remove skid plate. 3. Remove hub and lug nuts, then wheel and tire. 4. Remove CV shaft inner housing flange bolts, then support shaft at CV joints. 5. Separate stub shaft from hub bearing without pulling on rubber boot and remove shaft from vehicle. 6. Reverse procedure to install. Tighten flange bolts, and hub and lug nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments 1. Tighten adjusting nut to specifications while rotating hub. 2. Stop rotation and loosen adjusting nut, then tighten nut finger tight and install locknut and new cotter pin. 3. Endplay should be: 0.000-0.003 inch on 1995 models. 0.001-0.003 inch on 1996 models. 4. Clean grease cap, coat (do not fill) inside with wheel bearing grease and install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams Universal Joint: Diagrams Exploded View Of Single Cardan Type Universal Joint System Illustration shows typical single Cardan type universal joints. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes Universal Joint: Service and Repair Service Notes Before disassembling any universal joint, examine the assembly carefully and note the position of any grease fittings used. In addition, be sure to mark the yokes' relationship to the propeller shaft so they may be reassembled in the same relative position. Failure to observe these precautions may produce improper vehicle operating conditions that will result in rapid component wear and failure. When universal joints are disassembled for lubrication or inspection and the old parts are to be reinstalled, special care must be exercised to avoid damage to universal joint spider or cross and bearing cups. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 2812 Universal Joint: Service and Repair Single Cardan Joint With Universal Joint Replacement Tool Exploded View Of Single Cardan Type Universal Joint System DISASSEMBLE 1. Place driveshaft in a vise, using care to avoid damaging it. 2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place of snap rings. During servicing, the snap rings supplied with the replacement universal joint assembly must be used. 3. Position tool on shaft and press bearing out of yoke. If bearing cannot be pressed all the way out, remove it using vise grips or channel lock pliers or strike center yoke with hammer. Mark yoke and shaft to ensure they will be reassembled in their same relative positions. 4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side of flange. 5. If used, remove flange from spider. ASSEMBLE 1. Start new bearing into yoke, then position spider into yoke and press bearing until it is 1/4 inch below surface. 2. Remove tool and install a new snap ring. 3. Start new bearing in opposite side of yoke, then install tool and press on bearing until opposite bearing contacts snap ring. 4. Remove tool and install remaining snap ring. Without Universal Joint Replacement Tool Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 2813 Exploded View Of Single Cardan Type Universal Joint System DISASSEMBLE 1. Remove snap rings (or retainer plates) that retain bearings in yoke and driveshaft. 2. Place U-joint in a vise. Do not clamp sliding yoke or driveshaft tube in vise. Clamp only forged portion of sliding yoke or driveshaft yoke. To avoid yoke distortion, do not over tighten. 3. Select a wrench socket with an outside diameter slightly smaller than the U-joint bearings. Select another wrench socket with an inside diameter slightly larger than the U-joint bearings. 4. Place the sockets at opposite bearings in the yoke so that the smaller socket becomes a bearing pusher and the larger socket becomes a bearing receiver when the vise jaws come together. Close vise jaws until both bearings are free of yoke and remove bearings from the cross or spider. 5. If bearings will not come all the way out, close vise until bearing in receiver socket protrudes from yoke as much as possible without using excessive force. Then remove from vise and place that portion of bearing which protrudes from yoke between vise jaws. Tighten vise to hold bearing and drive yoke off with a soft hammer. 6. To remove opposite bearing from yoke, replace in vise with pusher socket on exposed cross journal with receiver socket over bearing cup. Then tighten vise jaws to press bearing back through yoke into receiving socket. 7. Remove yoke from driveshaft and again place protruding portion of bearing between vise jaws. Then tighten vise to hold bearing while driving yoke off bearing with soft hammer. 8. Turn spider or cross 1/4 turn and use the same procedure to press bearings out of driveshaft. ASSEMBLE 1. If old parts are to be reassembled, pack bearing cups with universal joint grease. Do not fill cups completely or use excessive amounts as over lubrication may damage seals during reassembly. Use new seals. 2. If new parts are being installed, check new bearings for adequate grease before assembling. 3. With the pusher (smaller) socket, press one bearing part way into driveshaft. Position spider into the partially installed bearing. Place second bearing into driveshaft. Fasten driveshaft in vise so that bearings are in contact with faces of vise jaws. Some spiders are provided with locating lugs which must face toward driveshaft when installed. 4. Press bearings all the way into position and install snap rings or retainer plates. 5. Install bearings in yoke in same manner. When installation is completed, check U-joint for binding or roughness. If free movement is impeded, Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 2814 correct the condition before installation in vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 2815 Universal Joint: Service and Repair Lubrication Lubrication of the CV joints should not be overlooked during the regular service intervals recommended by the manufacturer. During lubrication, use only the type of lubricant recommended by the manufacturer. This lubricant is usually lithium type chassis grease. Lubrication Fitting Adapter Lubrication Fitting Adapter & Fitting Location Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 2816 Double Cardan Lubrication Fitting Locations Lubrication fitting adapters and locations of the lubrication fittings are shown. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Torque Specification Torque Specification Torque Converter Bolt 23 ft. lbs. Driveplate to Crankshaft Bolt 55 ft. lb. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Torque Specification Torque Specification Flywheel to Crankshaft 2.5L 70 ft. lbs. Flywheel to Crankshaft 3.9L/5.2L 55 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 2828 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid AX-15 ................................................................................................................................................... ........................................................ 3.1L (6.6 Pints) NV3500 ............................................................. ............................................................................................................................................ 2.0L (4.2 Pints) NV4500 ..................................................................................................................................... .................................................................... 3.8L (8.0 Pints) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2841 Fluid - M/T: Fluid Type Specifications NV3500 ................................................................................................................................................ .......................................................... 2.0 L (2.1 qts.) AX15 .................................................................................................................................................... .......................................................... 3.1 L (3.3 qts.) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Specifications Power Take-Off: Specifications TYPE ................................................................................................................................................... ..................................................................... AP, AF CAPACITY, Refill NV-021 ................................................................................................................................................ ........................................... 2.1 Liters 4.6 Pints Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2855 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2856 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2862 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2863 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2864 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2868 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2869 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 2875 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2884 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 2890 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2894 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2895 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2899 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 2904 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 2905 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2909 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 2915 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 2924 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 2934 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation Overdrive Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2949 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 2955 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2962 Torque Converter Clutch Solenoid: Description and Operation CIRCUIT OPERATION The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and variable force solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T20 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T59, the PCM provides ground for the variable force solenoid. Circuit T59 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 2968 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2986 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2987 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2993 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 2994 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 2995 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 2999 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3000 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit T30. Circuit T30 connects to circuit C27. Circuit C27 connects to the coil side of the relay. Circuit T30 connects to cavity B30 of the PCM. When the PCM grounds the relay, the relay contacts connect circuit C26 from fuse B in the PDC to circuit C25. Circuit C25 connects to circuit T20. Circuit T20 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations > Page 3006 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3015 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3021 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3025 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3026 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3030 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor CIRCUIT OPERATION The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor > Page 3035 Transmission Speed Sensor: Description and Operation Transmission Speed Sensor CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 3036 Transmission Speed Sensor: Testing and Inspection Circuit T33 connects to circuit K7. Circuit K7 supplies 5 Volts to the vehicle speed sensor. Circuit K4 also provides ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3040 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit T33. Circuit T54 from the sensor connects to cavity E1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. Circuit K4 splices to circuit T35 which connects to the sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes Four-Wheel Drive (4WD) Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller, Anti-Lock Brakes (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four-Wheel Drive (4WD) Switch <--> [Four Wheel Drive Selector Switch] > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 3046 Four-Wheel Drive (4WD) Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit G107 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber lamp monitors anti-lock brake system condition. The lamp will be ON during engine starting, but should go off when the self-diagnostic system determines proper system operation. If the lamp remains ON, a malfunction in the anti-lock brake system is indicated. After diagnosis and repair of the system, the lamp may be turned OFF by disconnecting and reconnecting the anti-lock brake system control module electrical connector or the battery ground cable. The anti-lock brake system control module is located in the passenger compartment and can be accessed after removing the righthand cowl cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 3055 ABS Main Relay: Description and Operation CIRCUIT OPERATION When the Controller, Antilock Brakes (CAB) grounds the ABS power relay on circuit B116, the relay contacts close connecting circuit A1O from the Power Distribution Center (PDC) and circuit B120. Circuit A10 connects to fuse A in the PDC. Circuit A20 from the fuse 4 in the fuse block splices to feed the coil side of the ABS power relay From the ABS power relay, circuit B120 splices to supply voltage to the ABS pump motor and all solenoids in the hydraulic control unit. Circuit B120 also supplies power to the solenoids in the rear wheel anti-lock valve (RWAL). Additionally, circuit B120 provides an input to cavity 34 of the CAB. The input tells the CAB that voltage has been supplied to the pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Four Wheel ABS System Diagnostic Connector - ABS: Locations Four Wheel ABS System OBD II Diagnostic Connector. The ABS diagnostic connector is clipped to the underside of the knee bolster. The connector is positioned just below the steering column. The Anti Lock diagnostic functions have been integrated into the OBD II diagnostic connector located below the lefthand side of the instrument panel. If a diagnostic trouble code has been stored, both the brake and ABS warning lamps will be illuminated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Four Wheel ABS System > Page 3060 Diagnostic Connector - ABS: Locations Rear Wheel Anti-Lock (RWAL) System OBD II Diagnostic Connector. The ABS diagnostic connector is clipped to the underside of the knee bolster. The connector is positioned just below the steering column. The Rear Wheel Anti Lock (RWAL) diagnostic functions have been integrated into the OBD II diagnostic connector, located below the lefthand side of the instrument panel. If a diagnostic trouble code has been stored, both the brake and ABS warning lamps will be illuminated. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Description and Operation > Four Wheel Antilock Brakes Diagnostic Connector - ABS: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The DRB scan tool connects to the data link connector. Circuits D11 and D12 from the Controller, Antilock Brakes (CAB) connect to the data link connector. Circuit D12 connects to cavity 10 of the CAB. The CAB transmits data to the DRB scan tool on circuit D12. The DRB scan tool receives data from the CAB on circuit D11. Circuit D11 connects to cavity 11 of the CAB. Circuit A4 from fuse F in the Power Distribution Center (PDC) powers circuit M1 through PDC fuse 2. Circuit M1 supplies battery voltage to the data link connector. Circuit Z12 provides ground for the data link connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 3063 Diagnostic Connector - ABS: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION Circuit M1 supplies battery voltage to the data link connector. Circuit M1 originates at the fuse in cavity 2 of the Power Distribution Center (PDC). Circuit D20 connects to cavity C29 of the Powertrain Control Module (PCM). Circuit D20 is the SCI receive circuit for the PCM. Circuit D21 connects to cavity C27 of the PCM. Circuit D21 is the SCI transmit circuit for the PCM. Circuits Z8 and Z12 provide ground for the data link connector. Circuit B112 from the Controller Antilock Brakes (CAB) and circuit B113 from the rear wheel speed sensor connect to the data link connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System Electronic Brake Control Module: Service and Repair With Four Wheel Antilock System Fig 18 Releasing Main Harness Connector Fig 19 Removing Main Harness Connector From Module NOTE: The ABS module is located in the engine compartment attached to the forward side of the front brake anti-lock valve. ABS ELECTRONIC CONTROL MODULE REMOVAL 1. Disconnect upper harness connector from module. 2. Lift connector locking handle to release main harness connector from module. Rotate handle upward to clear connector. 3. Lift connector up and out of retaining lugs on module. 4. Remove screws attaching module to mounting bracket and remove module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 3068 Fig 20 ABS Electronic Control Module Installation ABS ELECTRONIC CONTROL MODULE INSTALLATION 1. Position module in mounting bracket and stall module attaching screws. 2. Connect main harness connector to module. Seat connector in module retaining lugs and start connector into module. Then rotate connector locking handle downward into l&ked; position to seat and retain connector. 3. Connect upper harness wires to module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 3069 Electronic Brake Control Module: Service and Repair With Rear Wheel Antilock System The ABS module is located behind the passenger's side of the instrument panel, near the defroster duct. 1. Disconnect battery ground cable. 2. Remove passenger side sill plate and cowl cover. 3. Remove control module to cowl attaching screws. 4. Disconnect electrical connector from module, then remove the module. 5. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Front Hydraulic Valve Hydraulic Control Assembly - Antilock Brakes: Description and Operation Front Hydraulic Valve CIRCUIT OPERATION Circuit B120 from the Antilock Brake System (ABS) power relay supplies voltage for the pump motor plus the isolation and dump solenoids in the hydraulic control unit. The Controller, Antilock Brakes (CAB), activates the pump motor and solenoids by providing separate ground paths for each. The CAB provides a ground path for the motor on circuit B60. The CAB cycles the isolation and dump solenoids in the hydraulic control unit by providing a ground path for each on separate circuits: - Circuit B248 connects to cavity 30 of the CAB and provides ground for the right front dump solenoid. - Circuit B249 connects to cavity 33 of the CAB and provides ground for the right front isolation solenoid. - Circuit B243 connects to cavity 35 of the CAB and provides ground for the left front dump solenoid. - Circuit B245 connects to cavity 37 of the CAB and provides ground for the left front isolation solenoid. There are two reset switches in the front hydraulic valve; a left switch and a right switch. Both switches provide inputs to the CAB. Circuit B5 from the left reset switch connects to the CAB at cavity 5 while circuit B18 from the right reset switch connects to cavity 18. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Front Hydraulic Valve > Page 3074 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Antilock Valve Circuit Operation With Four Wheel Antilock Brakes CIRCUIT OPERATION Circuit B120 from the ABS power relay supplies voltage for the isolation and dump solenoids in the Rear wheel Anti-Lock (RWAL) valve. The Controller, Anti-Lock Brakes (CAB), activates the solenoids by providing separate ground paths for each. - Circuit B254 connects to cavity 26 of the CAB and provides ground for the right rear dump solenoid. - Circuit B252 connects to cavity 28 of the CAB and provides ground for the right rear isolation solenoid. The RWAL valve has one reset switch that provides an input to the CAB. Circuit B19 from the reset switch connects to the CAB at cavity 19. With Rear Wheel Antilock Brakes CIRCUIT OPERATION The rear wheel anti-lock valve (RWAL) contains an isolation solenoid, a dump solenoid and a reset switch. Each is powered by the Controller, Antilock Brakes (CAB) on separate circuits. Circuit B108 from the CAB feeds the dump solenoid. The isolation solenoid is powered on circuit B101 from the CAB. Circuit Z9 provides ground for both solenoids. Circuit B111 from the CAB connects to the reset switch. The case grounded RWAL valve provides ground for the reset switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Page 3075 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection The hydraulic control unit is case grounded. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement 1. Disconnect battery ground cable. 2. Disconnect brake lines and electrical connections at anti-lock valve. 3. Remove anti-lock valve to stud plate screws, then lift anti-lock valve upward off studs and off bracket assembly. 4. Reverse procedure to install, noting the following: a. Torque valve attaching screws to 8-10 ft. lbs. b. Torque valve attaching nuts to 14-18 ft. lbs. c. Torque brake line fittings to 12-17 ft. lbs. d. Bleed brake system as described under Antilock Brake System/Service and Repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 3078 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement 1. Disconnect and remove battery to access valve lines. 2. Disconnect line to rear brakes at rear anti-lock valve. 3. Disconnect line to front brake anti-lock valve at combination valve. 4. Disconnect wire harness and ground wire at anti-lock and combination valves. 5. Remove combination valve retaining nuts. 6. Disconnect anti-lock valve to master cylinder lines. 7. Remove combination valve from master cylinder. Fig. 101 Rear Anti-Lock & Combination Valve Removal 8. Remove rear anti-lock valve, combination valve, bracket and lines as an assembly. 9. Remove line that connects anti-lock valve to combination valve. 10. Remove anti-lock valve from combination valve bracket. 11. If combination valve is to be replaced, remove connecting lines from valve. 12. Reverse procedure to install, noting the following: a. Install lines on valve, but do not tighten at this time. b. Install anti-lock valve on combination valve and install connecting lines. Do not tighten at this time. c. Install valve and bracket assembly on master cylinder and torque nuts to 16-21 ft. lbs. d. Install brake lines to master cylinder and torque fittings to 9-14 ft. lbs., then torque all remaining fittings to 12-16 ft. lbs. e. Bleed brakes as described under Antilock Brake System/Service and Repair and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3083 39 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3084 43 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3085 45 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3086 47 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3087 51 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3088 55 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3089 57 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3090 59 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3091 63 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3092 67 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3093 69 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3094 71 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3095 173 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3096 177 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3097 179 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3098 181 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3099 187 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3100 191 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3101 193 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3102 195 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3103 201 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3104 205 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3105 207 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3106 209 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3107 256 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 1 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 3110 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle. 2. Remove front wheels. 3. Remove disc brake caliper and support to frame using suitable wire. 4. Remove bolts attaching sensor to splash shield and steering knuckle. Retain special sensor bolts for installation. 5. Remove wire clamps and wire from control arm and steering knuckle. 6. Disconnect sensor harness connector and work sensor wire through fender panel, then remove sensor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque special sensor bolt to 13-18 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3113 Wheel Speed Sensor: Service and Repair Rear With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3114 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. On vehicles with disc brakes the brake pedal will require more pumping and frequent checking of fluid level in master cylinder during bleeding operation. Never use brake fluid that has been drained from hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and that the pad assemblies are properly seated. Before driving the vehicle, check brake operation to be sure that a firm pedal has been obtained. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3119 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Combination valve. 3. Rear anti-lock valve. 4. Front anti-lock valve. 5. Left rear wheel. 6. Right rear wheel. 7. Right front wheel. 8. Left front wheel. W/ Rear Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Front anti-lock valve. 3. Rear anti-lock valve. 4. Right rear wheel. 5. Left rear wheel. 6. Right front wheel. 7. Left front wheel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3120 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) 1. Install pressure bleeding tank part No. 3495-B, or equivalent, to master cylinder, then install metering valve hands off tool No. C-4121, or equivalent, to valve stem of metering valve. 2. On models equipped with RWAL, proceed as follows: a. Connect one end of a suitable hose to bleeder valve on RWAL hydraulic valve and submerge other end in a glass container partially filled with clean brake fluid. b. Open bleeder valve on RWAL hydraulic valve, and keep open until clear bubble free fluid flows from hose. 3. On all models, bleed one wheel at a time in order as follows: a. Right rear wheel. b. Left rear wheel. c. Right front wheel. d. Left front wheel. 4. Keep bleeder screws open until clear bubble free fluid flows from hose. 5. Repeat bleeding procedure if system indicator light stays On or if pedal feels spongy. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Four Wheel Antilock Brakes Brake Warning Indicator: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The Controller, Antilock Brakes (CAB) provides ground for the ABS warning lamp in the instrument cluster through the normally closed contacts in the ABS warning lamp relay. when the ignition switch is in the START position, the lamp illuminates as a bulb test for approx. 3 to 5 Seconds while the CAB performs a system self-test. While closed, the relay contacts complete the ground path for the ABS warning lamp by connecting circuit G19 from the lamp to ground on circuit Z1. Power for the lamp is supplied by circuit F14 from fuse 14 in the fuse block. If the system successfully completes the self-test, the CAB energizes the ABS warning lamp relay by grounding the relay coil on circuit B47. When the relay energizes, its contacts open and disconnect circuits G19 and Z1. Circuit A20 from fuse 4 in the fuse block supplies power to the coil side of the relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 3125 Brake Warning Indicator: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION The RWAL module provides ground for the instrument cluster Check Antilock warning lamp on circuit B102. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 3126 Brake Warning Indicator: Testing and Inspection 1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following: a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch, located in the brake line "T" fitting, mounted on frame rail in engine compartment below master cylinder. 3. On models with diesel engine, brake lamp is also connected to a sensor which monitors vacuum in brake booster system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 3132 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Piston Outside Diameter 2.6 in Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 3135 Brake Caliper: Specifications Brake Line Fittings 11 - 14 ft.lb Brake Shield Bolts 18 ft.lb Caliper Adapter Bolts 95 - 125 ft.lb Caliper Mounting Pins 18 - 26 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 3136 Brake Caliper: Service Precautions CALIPER INSPECTION If it is necessary to remove the caliper for installation of new parts, clean all parts in alcohol, wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly. Inspect piston bores in both housings for scoring or pitting. Bores that show light scratches or corrosion can usually be cleaned with crocus cloth. However, bores that have deep scratches or scoring may be honed, provided the diameter of the bore is not increased more than .002 inch. If the bore does not clean up within this specification, a new caliper housing should be installed (black stains on the bore walls are caused by piston seals and will do no harm). When using a hone, be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Remove all dust and grit by flushing the caliper with alcohol. Wipe dry with clean lint-free cloth and then clean a second time in the same manner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal 1. Raise vehicle, then remove front wheel. Fig. 5 Outboard Brake Pad Hold Down Spring Removal 2. Remove outboard brake pad hold down spring. 3. Disconnect brake hose at caliper and discard fitting washers if worn or damaged. 4. Remove caliper slide pins, then lift caliper and brake pads off rotor. 5. If necessary, remove brake pads from caliper as outlined under Brake Pad/Service and Repair. Installation 1. Install brake pads in caliper, then position caliper and pad assembly over rotor and into sliding ledges. Ensure brake pads are seated properly. 2. Align caliper with holes in adapter, then start both slide pins into holes by hand and tighten to specifications. 3. Connect brake hose to caliper and, if necessary, install new fitting washers. 4. Bleed hydraulic system as outlined under Hydraulic System/Service and Repair/Brake System Bleed, then install wheel and lower vehicle. 5. Apply brakes several times to ensure brake pads are fully seated. Ensure brake pedal is firm prior to operating vehicle. 6. Check and add brake fluid as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3139 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLE 1. Clean outside of caliper with suitable solvent. 2. Drain fluid from caliper and place clean shop cloths in caliper opposite piston. 3. Slowly apply compressed air to caliper inlet port until piston moves out of bore. Do not "blow" piston out of bore; damage and personal injury may result. 4. Remove and discard dust boot using a suitable screwdriver. Use care to avoid scratching caliper piston bore. 5. Remove and discard piston seal, using a suitable wooden or plastic tool. 6. Remove bleeder screw and protective cap, if equipped. 7. Remove and discard inner and outer bushings and plastic sleeves, if equipped. 8. Clean all components with clean brake fluid and compressed air. ASSEMBLE 1. Lubricate piston bore and new piston seal with clean brake fluid. 2. Install seal in bore groove by hand and lubricate piston with clean brake fluid. 3. Install new dust boot on piston, sliding metal retainer portion of boot over open end of piston and pulling boot rearward until boot lip seats in piston groove. 4. Push metal retainer portion of boot forward until retainer is flush with rim at open end of piston, then snap boot fold into place. 5. Install piston into caliper bore, using care to avoid unseating piston seal. 6. Press piston to bottom of bore. 7. Seat piston dust boot with installer tool No. C-4842 and handle tool No. C-4171, or equivalents. 8. Install bleeder screw, then new inner and outer bushings and plastic sleeves, if equipped, in caliper mounting ears. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal Brake Pad: Service and Repair Removal 1. Clean master cylinder reservoir and filler caps, then remove caps and drain approximately 1/4 of fluid from reservoir using a suitable suction tool. Fig. 5 Outboard Brake Pad Hold Down Spring Removal 2. Raise and support vehicle, then remove front wheel and outboard pad hold down spring. 3. Using a large C-clamp, bottom caliper piston by tightening clamp screw on outboard brake pad. Ensure rear of clamp is positioned on rear of caliper body. 4. Remove caliper slide pins, then lift caliper and brake pads out of adapter and off rotor surface. It is not necessary to disconnect caliper hydraulic line; however, caliper must be prevented from hanging on line. Support as necessary. 5. Remove outboard brake pad from caliper, then tilt inboard pad outward until retaining springs are clear of piston and remove pad. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 3144 Brake Pad: Service and Repair Installation Fig. 7 Caliper Adapter Lubrication Points 1. Clean and lubricate sliding surfaces of caliper mounting adapter. Use a wire brush to clean surfaces and Mopar Multi-Mileage Grease, or equivalent, to lubricate sliding surfaces and threads of slide pin holes. 2. Clean caliper slide pins with brake parts cleaner or suitable brake fluid, then coat pins with silicone grease. Replace severely corroded pins. 3. Install inboard brake pad and ensure retaining spring is fully seated in caliper piston, then position outboard pad in caliper mounting adapter. 4. Lower caliper into position over rotor and outboard brake pad, then align caliper in adapter and thread caliper slide pins in by hand. Fig. 8 Brake Pad Seating Inspection 5. Ensure brake pads are positioned correctly as shown, then tighten caliper slide pins to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 3145 Fig. 10 Outboard Brake Pad Retaining Spring Installation 6. Install outboard brake pad retaining spring as shown, then install wheel and lower vehicle. 7. Ensure brake fluid reservoir is full, then apply brakes several times to seat new brake pads. Ensure brake pedal is firm prior to operating vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Disc Brake Rotor Specifications Minimum Thickness .................................................................................................................... Specification is stamped or cast into the rotor hub surface Thickness Variation (Parallelism) ........................................................................................................ ................................................................... 0.0005 in Runout (TIR) ........................................................................................................................................ .................................................................... 0.004 in Finishes ............................................................................................................................................... ............................................................ 15-18 micro-in Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Brake Disc Service Brake Rotor/Disc: Service Precautions Brake Disc Service Servicing of disc brakes is extremely critical due to the close tolerances required in machining the brake disc to ensure proper brake operation. The maintenance of these close controls on the friction surfaces is necessary to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This close control of the rubbing surface finish is necessary to avoid pulls and erratic performance and promote long lining life and equal lining wear of both left and right brakes. Refinishing of the rubbing surfaces should not be attempted unless precision equipment, capable of measuring in micro-inches (millionths of an inch) is available. To check runout of a disc, mount a dial indicator on a convenient part (steering knuckle, tie rod, disc brake caliper housing) so that the plunger of the dial indicator contacts the disc at a point one inch from the outer edge. If the total indicated runout exceeds specifications, install a new disc. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Brake Disc Service > Page 3151 Brake Rotor/Disc: Service Precautions Brake Roughness The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. To check for this condition, measure the disc at 8 points with a micrometer at a radius approximately one inch from edge of disc. If thickness measurements vary more than specifications allow, the disc should be replaced with a new one. Excessive lateral runout of braking disc may cause a "knocking back" of the pistons, possibly creating increased pedal travel and vibration when brakes are applied. Before checking the runout, wheel bearings should be adjusted. Be sure to make the adjustment according to the recommendations given in that section. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Page 3152 Brake Rotor/Disc: Service and Repair 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and brake pads as outlined under Brake Pad/Service and Repair. NOTE: It is not necessary to disconnect brake line from caliper. After caliper has been removed from rotor, support it to prevent brake line damage. 3. Proceed as follows: a. Remove grease cap, cotter pin, hub nut lock, hub nut, thrust washer and outer wheel bearing. b. Remove rotor and hub assembly. Avoid damaging ABS tone wheel, located on rotor hub. c. If necessary, remove wheel bearing from rotor hub for rotor refinishing. 4. Reverse procedure to install, noting the following: a. Install new bearing grease seal and repack wheel bearings. After rotor installation, adjust wheel bearings by tightening nut (with wheel rotating) until bearing end play is 0-0.003 inch. b. Inspect ABS tone wheel for damage. Rotor assembly must be replaced if tone wheel is damaged. c. Tighten wheel lug nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Testing and Inspection Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications 9" Drum 10" Drum Brake Drum Inside Diameter 9 in 10 in Maximum Refinish Diameter 9.06 in 10.06 in Refer to limit stamped on drum. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3163 Brake Drum: Testing and Inspection Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor scores should be removed with sandpaper. Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. After a brake drum is machined, wipe the braking surface diameter with a cloth soaked in denatured alcohol. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions Brake Shoe: Service Precautions Prior to removing brake shoes it is recommended that a suitable clip or restraining device be applied to the wheel cylinders to prevent wheel cylinder pistons from being pushed out of their bores. Do not intermix automatic adjuster components from side to side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions > Page 3167 Brake Shoe: Testing and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions > Page 3168 Brake Shoe: Adjustments These brakes have self-adjusting shoe mechanisms that ensure correct lining to drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the car is moving rearward. Although the brakes are self-adjusting, an initial adjustment is necessary when the brake shoes have been relined, replaced or when the length of the star wheel adjuster has been changed during some other service operation. Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the automatic adjusters from functioning, thereby inducing low pedal heights. Should low pedal heights be encountered, it is recommended that numerous forward and reverse stops be made until satisfactory pedal height is obtained. NOTE: If a low pedal height condition cannot be corrected by making numerous reverse stops (provided the hydraulic system is free of air), it indicates that the self adjusting mechanism is not functioning. Therefore, it will be necessary to remove the drum, clean, free up and lubricate the adjusting mechanism. Then adjust the brakes, being sure the parking brake is fully released. ADJUSTMENT 1. Raise vehicle so wheels are free to turn, then remove rear adjusting hole cover. 2. Back off parking brake cable adjustment so there is slack in the cable. Ensure parking brake lever is fully released. 3. On models equipped with release type adjuster, insert adjusting tool into star wheel of adjusting screw. Move tool handle downward until slight drag is felt when wheel is rotated. 4. On models equipped with application type adjuster, insert adjusting tool into star wheel of adjusting screw. Move tool handle upward until slight drag is felt when wheel is rotated. 5. On all models, insert a suitable screwdriver into brake adjusting hole and push adjusting lever out of engagement with star wheel. Care should be taken not to bend adjusting lever. 6. Back off star wheel 10 to 12 notches until wheel rotates freely with no drag. 7. Install adjusting hole cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions > Page 3169 Brake Shoe: Service and Repair Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter With 9.00 Inch Drums 0.75 in With 10.00 Inch Drums 0.81 in Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 3174 Wheel Cylinder: Specifications Wheel Cylinder Attaching Screw 1/4 -20 8-14 ft.lb Wheel Cylinder Attaching Screw 5/16 -18 14-18 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. On vehicles with disc brakes the brake pedal will require more pumping and frequent checking of fluid level in master cylinder during bleeding operation. Never use brake fluid that has been drained from hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and that the pad assemblies are properly seated. Before driving the vehicle, check brake operation to be sure that a firm pedal has been obtained. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3180 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Combination valve. 3. Rear anti-lock valve. 4. Front anti-lock valve. 5. Left rear wheel. 6. Right rear wheel. 7. Right front wheel. 8. Left front wheel. W/ Rear Wheel Antilock Brakes The anti-lock brake system must be bled any time air enters the hydraulic system. It is important to note that excessive air in the brake system may set a primary pressure diagnostic trouble code in the control module. Pressure or manual bleeding procedures can be used when bleeding the ABS system after hoses or brake lines have been disconnected. Bleeding the ABS hydraulic system is also necessary after replacement of the hydraulic assembly or wheel brakes. During bleeding procedures, ensure the brake fluid level remains close to the Full mark on the reservoir. The brake lines may be pressure bled using a standard diaphragm type pressure bleeder. Only diaphragm type pressure bleeding equipment should be used in order to prevent air, moisture and other contaminants from entering the system. In addition, only DOT 3 brake fluid should be used. Perform bleeding procedure as outlined in the Hydraulic System/Service and Repair in the following order: 1. Master cylinder. 2. Front anti-lock valve. 3. Rear anti-lock valve. 4. Right rear wheel. 5. Left rear wheel. 6. Right front wheel. 7. Left front wheel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3181 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) 1. Install pressure bleeding tank part No. 3495-B, or equivalent, to master cylinder, then install metering valve hands off tool No. C-4121, or equivalent, to valve stem of metering valve. 2. On models equipped with RWAL, proceed as follows: a. Connect one end of a suitable hose to bleeder valve on RWAL hydraulic valve and submerge other end in a glass container partially filled with clean brake fluid. b. Open bleeder valve on RWAL hydraulic valve, and keep open until clear bubble free fluid flows from hose. 3. On all models, bleed one wheel at a time in order as follows: a. Right rear wheel. b. Left rear wheel. c. Right front wheel. d. Left front wheel. 4. Keep bleeder screws open until clear bubble free fluid flows from hose. 5. Repeat bleeding procedure if system indicator light stays On or if pedal feels spongy. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 3186 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Piston Outside Diameter 2.6 in Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 3189 Brake Caliper: Specifications Brake Line Fittings 11 - 14 ft.lb Brake Shield Bolts 18 ft.lb Caliper Adapter Bolts 95 - 125 ft.lb Caliper Mounting Pins 18 - 26 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 3190 Brake Caliper: Service Precautions CALIPER INSPECTION If it is necessary to remove the caliper for installation of new parts, clean all parts in alcohol, wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly. Inspect piston bores in both housings for scoring or pitting. Bores that show light scratches or corrosion can usually be cleaned with crocus cloth. However, bores that have deep scratches or scoring may be honed, provided the diameter of the bore is not increased more than .002 inch. If the bore does not clean up within this specification, a new caliper housing should be installed (black stains on the bore walls are caused by piston seals and will do no harm). When using a hone, be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Remove all dust and grit by flushing the caliper with alcohol. Wipe dry with clean lint-free cloth and then clean a second time in the same manner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal 1. Raise vehicle, then remove front wheel. Fig. 5 Outboard Brake Pad Hold Down Spring Removal 2. Remove outboard brake pad hold down spring. 3. Disconnect brake hose at caliper and discard fitting washers if worn or damaged. 4. Remove caliper slide pins, then lift caliper and brake pads off rotor. 5. If necessary, remove brake pads from caliper as outlined under Brake Pad/Service and Repair. Installation 1. Install brake pads in caliper, then position caliper and pad assembly over rotor and into sliding ledges. Ensure brake pads are seated properly. 2. Align caliper with holes in adapter, then start both slide pins into holes by hand and tighten to specifications. 3. Connect brake hose to caliper and, if necessary, install new fitting washers. 4. Bleed hydraulic system as outlined under Hydraulic System/Service and Repair/Brake System Bleed, then install wheel and lower vehicle. 5. Apply brakes several times to ensure brake pads are fully seated. Ensure brake pedal is firm prior to operating vehicle. 6. Check and add brake fluid as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3193 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLE 1. Clean outside of caliper with suitable solvent. 2. Drain fluid from caliper and place clean shop cloths in caliper opposite piston. 3. Slowly apply compressed air to caliper inlet port until piston moves out of bore. Do not "blow" piston out of bore; damage and personal injury may result. 4. Remove and discard dust boot using a suitable screwdriver. Use care to avoid scratching caliper piston bore. 5. Remove and discard piston seal, using a suitable wooden or plastic tool. 6. Remove bleeder screw and protective cap, if equipped. 7. Remove and discard inner and outer bushings and plastic sleeves, if equipped. 8. Clean all components with clean brake fluid and compressed air. ASSEMBLE 1. Lubricate piston bore and new piston seal with clean brake fluid. 2. Install seal in bore groove by hand and lubricate piston with clean brake fluid. 3. Install new dust boot on piston, sliding metal retainer portion of boot over open end of piston and pulling boot rearward until boot lip seats in piston groove. 4. Push metal retainer portion of boot forward until retainer is flush with rim at open end of piston, then snap boot fold into place. 5. Install piston into caliper bore, using care to avoid unseating piston seal. 6. Press piston to bottom of bore. 7. Seat piston dust boot with installer tool No. C-4842 and handle tool No. C-4171, or equivalents. 8. Install bleeder screw, then new inner and outer bushings and plastic sleeves, if equipped, in caliper mounting ears. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 051495A > Feb > 96 > Brake Pedal - Squawk Noise When Depressed Brake Proportioning/Combination Valve: Customer Interest Brake Pedal - Squawk Noise When Depressed NO: 05-14-95 Rev. A GROUP: Brakes DATE: Feb. 9, 1996 SUBJECT: Brake Pedal Noise When Depressed NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-14-95 DATED DECEMBER 8, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. DAKOTA (AN) HAS BEEN ADDED AND IS MARKED WITH **ASTERISKS**. MODELS: 1995 - 1996 (BR) Ram Truck **1995 - 1996 (AN) Dakota** SYMPTOM/CONDITION: A squawk type noise may be heard when the brake pedal is depressed. DIAGNOSIS: Depress the brake pedal several times to verify the complaint. If the noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 4874841 Metering Valve Kit REPAIR PROCEDURE: This bulletin involves installing a revised back-up plate into the brake combination valve. This bulletin does not apply to combination valves identified with a green dot. The valves with the green dot have the current back up plate. CAUTION: USE CARE WHEN PERFORMING THIS PROCEDURE. ANY DIRT THAT ENTERS THE COMBINATION VALVE MAY IMPEDE THE OPERATION OF THE VALVE. 1. Clean the combination valve in the area around the metering valve with Mopar Brake Parts Cleaner (P/N 4549623) to prevent dirt from entering the valve when it is disassembled. CAUTION: DO NOT ALLOW BRAKE CLEANER TO COME INTO CONTACT WITH ANY INTERNAL COMBINATION VALVE COMPONENTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 051495A > Feb > 96 > Brake Pedal - Squawk Noise When Depressed > Page 3205 2. Remove the metering valve and discard the plastic back up plate. A metal plate is provided in the metering valve kit (P/N 4874841). Figure 1 3. Clean the opening in the combination valve with the lint free towel supplied in the kit. 4. Assemble the metering valve as shown in Figure 2. Make sure that the flat side of the metal back-up plate is toward the threaded plug as shown. 5. Install the metering valve and torque to 15 ft. lbs. (20 Nm) 6. Manually bleed both front calipers. Do not use a pressure bleeder. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-30-17-92 0.4 Hrs. Install Metering Valve Kit 1995-96 (BR)(AN) Into Brake Combination Valve FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 051495A > Feb > 96 > Brake Pedal - Squawk Noise When Depressed Brake Proportioning/Combination Valve: All Technical Service Bulletins Brake Pedal - Squawk Noise When Depressed NO: 05-14-95 Rev. A GROUP: Brakes DATE: Feb. 9, 1996 SUBJECT: Brake Pedal Noise When Depressed NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-14-95 DATED DECEMBER 8, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. DAKOTA (AN) HAS BEEN ADDED AND IS MARKED WITH **ASTERISKS**. MODELS: 1995 - 1996 (BR) Ram Truck **1995 - 1996 (AN) Dakota** SYMPTOM/CONDITION: A squawk type noise may be heard when the brake pedal is depressed. DIAGNOSIS: Depress the brake pedal several times to verify the complaint. If the noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 4874841 Metering Valve Kit REPAIR PROCEDURE: This bulletin involves installing a revised back-up plate into the brake combination valve. This bulletin does not apply to combination valves identified with a green dot. The valves with the green dot have the current back up plate. CAUTION: USE CARE WHEN PERFORMING THIS PROCEDURE. ANY DIRT THAT ENTERS THE COMBINATION VALVE MAY IMPEDE THE OPERATION OF THE VALVE. 1. Clean the combination valve in the area around the metering valve with Mopar Brake Parts Cleaner (P/N 4549623) to prevent dirt from entering the valve when it is disassembled. CAUTION: DO NOT ALLOW BRAKE CLEANER TO COME INTO CONTACT WITH ANY INTERNAL COMBINATION VALVE COMPONENTS. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 051495A > Feb > 96 > Brake Pedal - Squawk Noise When Depressed > Page 3211 2. Remove the metering valve and discard the plastic back up plate. A metal plate is provided in the metering valve kit (P/N 4874841). Figure 1 3. Clean the opening in the combination valve with the lint free towel supplied in the kit. 4. Assemble the metering valve as shown in Figure 2. Make sure that the flat side of the metal back-up plate is toward the threaded plug as shown. 5. Install the metering valve and torque to 15 ft. lbs. (20 Nm) 6. Manually bleed both front calipers. Do not use a pressure bleeder. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-30-17-92 0.4 Hrs. Install Metering Valve Kit 1995-96 (BR)(AN) Into Brake Combination Valve FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Hold-Off Valve Brake Proportioning/Combination Valve: Description and Operation Hold-Off Valve Some vehicles incorporate a hold-off valve, usually in combination with the brake warning switch. This valve holds off hydraulic pressure to the front disc brakes to a given psi range. This allows the rear drum brake shoes to overcome the return springs and begin to contact drums. This action helps prevent locking of the front brakes on icy surfaces under light braking conditions. This valve has no effect on front brake pressure during hard stopping. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Hold-Off Valve > Page 3214 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve There are two basic types of proportioning valves, one of which is height sensitive. Vehicles may have either one or both of these valves. On the first type, the proportioning valve operates by transmitting full input pressure to the rear brakes up to a certain point, called the split point, then reducing the amount of pressure increase to the rear brakes beyond the split point according to a certain ratio. On light pedal applications, approximately equal brake pressure is transmitted to both front and rear brakes, while at higher pressures, pressure transmitted to rear brakes is lower than that transmitted to front brakes to prevent premature rear wheel lock-up. If hydraulic pressure is lost in front brake system, rear brake system hydraulic pressure moves the brake warning switch piston, opening a bypass in the proportioning valve to allow full rear brake hydraulic pressure. Fig. 1 Typical height sensing proportioning valve The height sensing type of proportioning valve is located under the load bed just forward of the rear axle. This valve automatically provides optimum front-to-rear brake balance regardless of vehicle load. Pressure to the rear brakes is modulated by the proportioning valve sensing vehicle load through relative movement between rear axle and load floor. The valve is mounted to a load floor crossmember. A large external spring is connected between a lever mounted on the valve and an adjustable bracket mounted on the rear axle. Higher brake line pressure is allowed as the load increases. The proportioning valve transmits full input pressure to rear brakes up to a certain point called the split point, and beyond that point reduces the amount of pressure increase to the rear brakes according to a certain ratio, preventing premature wheel lock-up. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 3215 Brake Proportioning/Combination Valve: Testing and Inspection These models use a proportioning valve and pressure differential switch, or a combination valve. When a premature rear wheel skid is obtained during braking, it may be an indication of an improperly adjusted valve. Air in bypass line or a malfunction may have occurred within the valve. First bleed and readjust valve. If problem is not resolved, proceed as follows to test valve assembly: Fig. 4 Height Sensing Proportioning Valve Assembly 1. Remove actuator assembly adjustment nut, then the actuator arm assembly from valve lever. 2. Install one gauge and Tee from line pressure set No. C-4007-A, or equivalent, between brake line from combination valve to input port of proportioning valve. 3. Install second gauge from line pressure set No. C-4007-A, or equivalent, directly to valve output port. Bleed rear brake system including two bleeder screws on valve. 4. Have an assistant exert pressure on the brake pedal to obtain a pressure reading of 1000 psi on gauge to valve inlet port. Gauge on output port should read 225-325 psi. If not, replace valve and torque mounting bolts to 100 inch lbs. 5. If both gauges read correctly, reinstall actuator arm assembly, adjust, and bleed rear brakes and valve, then road test vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Front Hydraulic Valve Hydraulic Control Assembly - Antilock Brakes: Description and Operation Front Hydraulic Valve CIRCUIT OPERATION Circuit B120 from the Antilock Brake System (ABS) power relay supplies voltage for the pump motor plus the isolation and dump solenoids in the hydraulic control unit. The Controller, Antilock Brakes (CAB), activates the pump motor and solenoids by providing separate ground paths for each. The CAB provides a ground path for the motor on circuit B60. The CAB cycles the isolation and dump solenoids in the hydraulic control unit by providing a ground path for each on separate circuits: - Circuit B248 connects to cavity 30 of the CAB and provides ground for the right front dump solenoid. - Circuit B249 connects to cavity 33 of the CAB and provides ground for the right front isolation solenoid. - Circuit B243 connects to cavity 35 of the CAB and provides ground for the left front dump solenoid. - Circuit B245 connects to cavity 37 of the CAB and provides ground for the left front isolation solenoid. There are two reset switches in the front hydraulic valve; a left switch and a right switch. Both switches provide inputs to the CAB. Circuit B5 from the left reset switch connects to the CAB at cavity 5 while circuit B18 from the right reset switch connects to cavity 18. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Front Hydraulic Valve > Page 3220 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Antilock Valve Circuit Operation With Four Wheel Antilock Brakes CIRCUIT OPERATION Circuit B120 from the ABS power relay supplies voltage for the isolation and dump solenoids in the Rear wheel Anti-Lock (RWAL) valve. The Controller, Anti-Lock Brakes (CAB), activates the solenoids by providing separate ground paths for each. - Circuit B254 connects to cavity 26 of the CAB and provides ground for the right rear dump solenoid. - Circuit B252 connects to cavity 28 of the CAB and provides ground for the right rear isolation solenoid. The RWAL valve has one reset switch that provides an input to the CAB. Circuit B19 from the reset switch connects to the CAB at cavity 19. With Rear Wheel Antilock Brakes CIRCUIT OPERATION The rear wheel anti-lock valve (RWAL) contains an isolation solenoid, a dump solenoid and a reset switch. Each is powered by the Controller, Antilock Brakes (CAB) on separate circuits. Circuit B108 from the CAB feeds the dump solenoid. The isolation solenoid is powered on circuit B101 from the CAB. Circuit Z9 provides ground for both solenoids. Circuit B111 from the CAB connects to the reset switch. The case grounded RWAL valve provides ground for the reset switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Page 3221 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection The hydraulic control unit is case grounded. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve Replacement 1. Disconnect battery ground cable. 2. Disconnect brake lines and electrical connections at anti-lock valve. 3. Remove anti-lock valve to stud plate screws, then lift anti-lock valve upward off studs and off bracket assembly. 4. Reverse procedure to install, noting the following: a. Torque valve attaching screws to 8-10 ft. lbs. b. Torque valve attaching nuts to 14-18 ft. lbs. c. Torque brake line fittings to 12-17 ft. lbs. d. Bleed brake system as described under Antilock Brake System/Service and Repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 3224 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve Replacement 1. Disconnect and remove battery to access valve lines. 2. Disconnect line to rear brakes at rear anti-lock valve. 3. Disconnect line to front brake anti-lock valve at combination valve. 4. Disconnect wire harness and ground wire at anti-lock and combination valves. 5. Remove combination valve retaining nuts. 6. Disconnect anti-lock valve to master cylinder lines. 7. Remove combination valve from master cylinder. Fig. 101 Rear Anti-Lock & Combination Valve Removal 8. Remove rear anti-lock valve, combination valve, bracket and lines as an assembly. 9. Remove line that connects anti-lock valve to combination valve. 10. Remove anti-lock valve from combination valve bracket. 11. If combination valve is to be replaced, remove connecting lines from valve. 12. Reverse procedure to install, noting the following: a. Install lines on valve, but do not tighten at this time. b. Install anti-lock valve on combination valve and install connecting lines. Do not tighten at this time. c. Install valve and bracket assembly on master cylinder and torque nuts to 16-21 ft. lbs. d. Install brake lines to master cylinder and torque fittings to 9-14 ft. lbs., then torque all remaining fittings to 12-16 ft. lbs. e. Bleed brakes as described under Antilock Brake System/Service and Repair and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Adjustments Load Compensator: Adjustments 1. Vehicle must be sitting on all four wheels at curb weight. 2. Loosen locknut on follower bolt attached to lever assembly. 3. Adjust follower to a point where rubber bumper just contacts underside of leaf spring, then turn follower bolt clockwise three to four more revolutions. 4. Hold follower bolt in position and torque locknut to 25 ft. lbs. Fig. 5 Actuator Assembly Compression Spring 5. Prior to adjusting actuator assembly, compression spring within cage must be completely compressed with plastic guides parallel to one another. A wooden wedge can be used for this purpose. 6. Loosen adjusting nut on actuator and ensure it is properly seated in valve lever. 7. Bottom valve lever by pushing it toward valve body (apply force by pushing on spring hook). 8. While holding lever in position, torque adjusting nut to 95 inch lbs. 9. Remove wedge from cage of actuator assembly and road test vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Component .......................................................................................................................................... ...................................................... Torque /Ft. Lbs. Brake Booster Mounting Bolts ............................................................................................................. ...................................................................... 16 - 25 Brake Line Fittings ............................................ ......................................................................................................................................................... 11 - 14 Brake Shield Bolts ........................................................................................................................ ..................................................................................... 18 Caliper Adapter Bolts ................................ .............................................................................................................................................................. . 95 - 125 Caliper Mounting Pins ......................................................................................................... ....................................................................................... 18 - 26 Master Cylinder Mounting Bolts ...... .............................................................................................................................................................. ............ 18 - 20 Wheel Lug Nuts .......................................................................................................... .............................................................................................. 85 - 117 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding 1. On models equipped with Rear Wheel Anti-Lock brakes (RWAL), connect one end of a suitable hose to bleeder valve on RWAL hydraulic valve and submerge other end in a glass container partially filled with clean brake fluid. 2. Pump brake pedal several times, then hold pedal down firmly. 3. With pedal firmly depressed, open bleeder valve until pedal fades to floor, then close bleeder valve. 4. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. Ensure a fluid level is maintained in master cylinder at all times. 5. On all models, perform Steps 2, 3 and 4 on right rear, left rear, right front and left front brake in that order. 6. After bleeding of brakes is completed, road test vehicle to ensure brakes are operating correctly and pedal is solid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3233 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Without Aluminum Master Cylinder 1. Disconnect brake lines from master cylinder. Install plugs in outlets to prevent fluid leakage. 2. Remove nuts that attach master cylinder to cowl panel or power brake unit, if equipped. 3. Disconnect pedal pushrod (manual brakes) from brake pedal. 4. Slide master cylinder straight out from cowl panel and/or power brake unit. 5. Reverse procedure to install. With Manual Brakes 1. Disconnect brake lines from master cylinder. Install plugs in outlets to prevent fluid leakage. 2. From under instrument panel, disconnect stop lamp switch mounting bracket and position aside. 3. Grasp brake pedal and pull backward to disengage pushrod from master cylinder piston. This will require a pull of about 50 lbs. Also, the retention grommet will be destroyed. 4. Remove master cylinder to cowl retaining nuts and remove master cylinder by pulling straight out. Make sure to remove all traces of old grommet from pushrod groove and master cylinder piston. 5. Reverse procedure to install. Install new grommet on pushrod, then lubricate grommet with water and align pushrod with master cylinder piston. Using brake pedal, apply pressure to fully seat pushrod into piston. With Power Brakes 1. Disconnect primary and secondary brake tubes from master cylinder, then cap lines and master cylinder fitting. 2. Remove nuts attaching master cylinder to power brake unit, then slide master cylinder from power brake unit. 3. Reverse procedure to install. With ABS 1. Using a suitable flare nut wrench, remove brake lines from master cylinder to combination valve. 2. Disconnect brake line from the Rear Wheel Anti-Lock (RWAL) valve to combination valve. 3. Disconnect harness wires from RWAL valve and combination valve switch. 4. Disconnect anti-lock harness ground wire from combination valve bracket. 5. Remove nuts attaching combination valve bracket and master cylinder to brake booster mounting studs. 6. Slide combination valve bracket off of booster mounting studs, then remove master cylinder. 7. Reverse procedure to install, noting the following: a. Ensure brake booster push rod is aligned and seated in primary piston. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3234 Fig. 9 Master Cylinder Replacement b. Install all brake line fittings hand tight, then install rear brake anti-lock valve in combination valve bracket. Ensure bracket tab is seated in valve before installing valve attaching bolt. c. Torque valve attaching bolt to 13 ft. lbs. d. Torque valve and cylinder brake lines to 140-200 inch lbs. e. Torque master cylinder mounting bolts to 200-300 inch lbs. f. Fill and bleed brake system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter With 9.00 Inch Drums 0.75 in With 10.00 Inch Drums 0.81 in Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 3239 Wheel Cylinder: Specifications Wheel Cylinder Attaching Screw 1/4 -20 8-14 ft.lb Wheel Cylinder Attaching Screw 5/16 -18 14-18 ft.lb Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation CIRCUIT OPERATION Ground for the park brake lamp is supplied through the case grounded park brake switch on circuit G11. If the vehicle is equipped with Rear Wheel Antilock (RWAL) brakes, circuit 011 provides an input to the Controller, Antilock Brakes (CAB) and splices to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 3251 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Page 3252 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Recalls for Vacuum Brake Booster: > NHTSA95V199000 > Oct > 95 > Recall 95V199000: Brake Power Booster Hose Not Clamped Vacuum Brake Booster: Recalls Recall 95V199000: Brake Power Booster Hose Not Clamped THE POWER BRAKE BOOSTER VACUUM HOSE COULD BE IMPROPERLY INSTALLED AND NOT CLAMPED TO THE BRAKE BOOSTER VACUUM NIPPLE. A DISCONNECTED VACUUM HOSE CAN CAUSE AN INCREASE IN ENGINE IDLE SPEED AND LOSS OF BRAKE POWER ASSIST DURING BRAKE APPLICATION WITHOUT PRIOR WARNING. DEALERS WILL INSPECT THE VEHICLES TO INSURE THAT THE BRAKE BOOSTER VACUUM HOSE CONNECTION IS FULLY SEATED AND CLAMPED TO THE VACUUM CHECK VALVE NIPPLE AT THE BRAKE BOOSTER. SYSTEM: BRAKES; HYDRAULIC; POWER ASSIST; VACUUM SYSTEM. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS EQUIPPED WITH 2.5L ENGINE. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1996 DODGE TRUCK DAKOTA Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > NHTSA95V199000 > Oct > 95 > Recall 95V199000: Brake Power Booster Hose Not Clamped Vacuum Brake Booster: All Technical Service Bulletins Recall 95V199000: Brake Power Booster Hose Not Clamped THE POWER BRAKE BOOSTER VACUUM HOSE COULD BE IMPROPERLY INSTALLED AND NOT CLAMPED TO THE BRAKE BOOSTER VACUUM NIPPLE. A DISCONNECTED VACUUM HOSE CAN CAUSE AN INCREASE IN ENGINE IDLE SPEED AND LOSS OF BRAKE POWER ASSIST DURING BRAKE APPLICATION WITHOUT PRIOR WARNING. DEALERS WILL INSPECT THE VEHICLES TO INSURE THAT THE BRAKE BOOSTER VACUUM HOSE CONNECTION IS FULLY SEATED AND CLAMPED TO THE VACUUM CHECK VALVE NIPPLE AT THE BRAKE BOOSTER. SYSTEM: BRAKES; HYDRAULIC; POWER ASSIST; VACUUM SYSTEM. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS EQUIPPED WITH 2.5L ENGINE. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1996 DODGE TRUCK DAKOTA Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3267 Vacuum Brake Booster: Specifications Component .......................................................................................................................................... ...................................................... Torque /Ft. Lbs. Brake Booster Mounting Bolts ............................................................................................................. ...................................................................... 16 - 25 Brake Line Fittings ............................................ ......................................................................................................................................................... 11 - 14 Brake Shield Bolts ........................................................................................................................ ..................................................................................... 18 Caliper Adapter Bolts ................................ .............................................................................................................................................................. . 95 - 125 Caliper Mounting Pins ......................................................................................................... ....................................................................................... 18 - 26 Master Cylinder Mounting Bolts ...... .............................................................................................................................................................. ............ 18 - 20 Wheel Lug Nuts .......................................................................................................... .............................................................................................. 85 - 117 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 3268 Vacuum Brake Booster: Description and Operation These units are self contained vacuum hydraulic power braking units. They are the vacuum suspended type which use engine intake manifold vacuum and atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral with the vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied to valve operating rod through the brake pedal linkage. The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric port is a part of the valve plunger which moves within the valve housing and vacuum power diaphragm assembly. These units require no maintenance and must be replaced as a complete assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Unit Service Vacuum Brake Booster: Service and Repair Power Brake Unit Service The only serviceable power brake booster components are the vacuum hose and the check valve. NOTE: The power brake booster must be serviced as an assembly. If diagnosis indicates a power brake booster fault, the unit must be replaced as an assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Unit Service > Page 3271 Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement Fig. 1 Power Booster And Brake Pedal Components Fig. 2 Master Cylinder Mounting POWER BRAKE BOOSTER REMOVAL 1. Disconnect brake lines at master cylinder. 2. Remove ground wire from combination valve bracket. 3. Remove nuts attaching master cylinder to mounting studs on power brake booster. 4. Slide combination valve bracket off cylinder mounting studs. Loosen or disconnect brake lines at rear antilock valve and combination valve if necessary. 5. Remove master cylinder. 6. Disconnect vacuum lines at booster. 7. Remove clip securing booster push rod to brake pedal. 8. Remove nuts from booster mounting studs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Unit Service > Page 3272 9. Remove booster and gasket from dash panel. POWER BRAKE BOOSTER INSTALLATION 1. Position gasket on booster studs. 2. Guide booster studs into dash panel holes and seat booster on panel. 3. Install and tighten booster attaching nuts to 28 Nm (250 in. lbs). 4. Install booster push rod on brake pedal. Secure rod to pedal with retaining clip. 5. Install booster check valve if removed and connect vacuum hose to check valve. 6. Position master cylinder on brake booster mounting studs. 7. Slide combination valve bracket onto cylinder mounting studs. 8. Install and tighten cylinder mounting nuts to 28 Nm (250 in. lbs). 9. Connect brake lines to master cylinder. Tighten line fittings to 19 Nm (170 in. lbs). 10. Connect ground wire to combination valve bracket. 11. Tighten any brake lines at combination valve and rear antilock valve, if loosened or disconnected. 12. Fill and bleed brake system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 3277 ABS Main Relay: Description and Operation CIRCUIT OPERATION When the Controller, Antilock Brakes (CAB) grounds the ABS power relay on circuit B116, the relay contacts close connecting circuit A1O from the Power Distribution Center (PDC) and circuit B120. Circuit A10 connects to fuse A in the PDC. Circuit A20 from the fuse 4 in the fuse block splices to feed the coil side of the ABS power relay From the ABS power relay, circuit B120 splices to supply voltage to the ABS pump motor and all solenoids in the hydraulic control unit. Circuit B120 also supplies power to the solenoids in the rear wheel anti-lock valve (RWAL). Additionally, circuit B120 provides an input to cavity 34 of the CAB. The input tells the CAB that voltage has been supplied to the pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System Electronic Brake Control Module: Service and Repair With Four Wheel Antilock System Fig 18 Releasing Main Harness Connector Fig 19 Removing Main Harness Connector From Module NOTE: The ABS module is located in the engine compartment attached to the forward side of the front brake anti-lock valve. ABS ELECTRONIC CONTROL MODULE REMOVAL 1. Disconnect upper harness connector from module. 2. Lift connector locking handle to release main harness connector from module. Rotate handle upward to clear connector. 3. Lift connector up and out of retaining lugs on module. 4. Remove screws attaching module to mounting bracket and remove module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 3282 Fig 20 ABS Electronic Control Module Installation ABS ELECTRONIC CONTROL MODULE INSTALLATION 1. Position module in mounting bracket and stall module attaching screws. 2. Connect main harness connector to module. Seat connector in module retaining lugs and start connector into module. Then rotate connector locking handle downward into l&ked; position to seat and retain connector. 3. Connect upper harness wires to module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 3283 Electronic Brake Control Module: Service and Repair With Rear Wheel Antilock System The ABS module is located behind the passenger's side of the instrument panel, near the defroster duct. 1. Disconnect battery ground cable. 2. Remove passenger side sill plate and cowl cover. 3. Remove control module to cowl attaching screws. 4. Disconnect electrical connector from module, then remove the module. 5. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 3292 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 3293 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3298 39 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3299 43 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3300 45 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3301 47 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3302 51 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3303 55 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3304 57 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3305 59 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3306 63 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3307 67 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3308 69 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3309 71 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3310 173 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3311 177 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3312 179 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3313 181 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3314 187 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3315 191 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3316 193 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3317 195 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3318 201 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3319 205 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3320 207 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3321 209 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3322 256 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 1 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 3325 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle. 2. Remove front wheels. 3. Remove disc brake caliper and support to frame using suitable wire. 4. Remove bolts attaching sensor to splash shield and steering knuckle. Retain special sensor bolts for installation. 5. Remove wire clamps and wire from control arm and steering knuckle. 6. Disconnect sensor harness connector and work sensor wire through fender panel, then remove sensor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque special sensor bolt to 13-18 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3328 Wheel Speed Sensor: Service and Repair Rear With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3329 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 3335 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 3336 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 3343 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 3344 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 3345 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 3346 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 3350 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 3351 Neutral Safety Switch: Description and Operation When closed, the case-grounded PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 3352 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 3353 Neutral Safety Switch: Service and Repair 1. Raise and support vehicle, then position drain pan under switch. 2. Disconnect switch wires and remove switch from case. 3. Ensure switch operating lever fingers center in case opening for switch when shift lever is in Park and Neutral positions. 4. Install switch and new seal. Torque switch to 25 ft. lbs. 5. Connect switch wires, lower vehicle and check transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3358 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3359 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3360 Starter Relay: Testing and Inspection Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 3365 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 3366 Battery Temperature Sensor: Description and Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Alternator ID. ....................................................................................................................................................... Output Amps @ 15 Volts, 1250 RPM 4557301 ............................................................................................................................................... ...................................................................... 75 [02] 5234031 ............................................................ ......................................................................................................................................................... 90 [02] 5234208 ........................................................................................................................................ ........................................................................... 120 [02] 53008646 ................................................... .............................................................................................................................................................. .. 75 [02] 53008647 .............................................................................................................................. ..................................................................................... 90 [02] 53008651 ........................................... .............................................................................................................................................................. ........ 120 [02] Footnotes: [02] -- Maximum. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3371 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3372 Alternator: Application and ID ID No. .................................................................................................................................................. .............................. 53008646, 53008647, 53008651 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3373 Alternator: Description and Operation The main components of the alternator are the rotor, stator, rectifier, end shields and drive pulley. Direct current is available at the output "B+" terminal. Alternator output is controlled by voltage regulator circuitry contained within the power and logic modules of the Engine Controller. The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Alternator: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CHECK ENGINE LAMP To start the function, cycle ignition switch ON-OFF-ON-OFF-ON within 5 seconds and any stored fault code will appear. Check engine lamp will display the code by flashing on and off. There is a short pause between flashes and a longer pause between digits. All codes displayed are 2 digit numbers with a 4 second pause between codes. The lamp will flash until all codes are displayed then 55 (end test) will appear. SCAN TOOL 1. On 1994-95 models, connect DRB test tool or equivalent scan tool, to Diagnostic Link Connector (DCL) located under the hood. 2. On 1996 models, connect DRB test tool or equivalent scan tool, to DCL located under the instrument panel. 3. On all models, follow scan tool manufactures instructions to access Diagnostic Trouble Codes (DTCs). Clearing Diagnostic Trouble Codes Diagnostic Trouble Codes (DTCs) may only be cleared with the use of a suitable scan tool. Follow scan tool manufacturers instructions to clear DTCs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 3376 Alternator: Component Tests and General Diagnostics Troubleshooting Fig 1 Charging System Diagnosis Chart Alternator Output Wire Resistance Test TEST PROCEDURE 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 3377 Fig 2 Alternator Output Wire Resistance Test Fig 3 Alternator Output Wire Resistance Test 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead wire of a suitable voltmeter to disconnected "B+" lead wire, then connect negative lead to battery positive post. 5. Remove air hose between Engine Controller and air cleaner. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 3378 Fig. 4 Alternator Connections (Plug Type) Fig. 5 Alternator Connections (Nut Type) 6. Connect suitable jumper wire to ground and K20 (field driver) terminal at rear of alternator. This may generate a fault code. Do not connect powered field circuit to ground, as component damage will occur. 7. Connect a suitable engine tachometer, then reconnect battery ground cable. 8. Ensure carbon pile is in OPEN or OFF position, then connect a variable carbon pile rheostat to battery terminals. 9. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a 20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed 0.5 volt. TEST RESULTS 1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging circuit. A voltage drop inspection may be performed at each connector to locate point of excessive resistance. 2. If charging circuit resistance inspection was satisfactory, disconnect battery ground cable, then the ammeter, voltmeter, carbon pile and tachometer. 3. Remove jumper wire. 4. Connect battery ground cable, then the hose between Engine Controller and air cleaner. 5. Erase codes using DRB inspection tool or equivalent scan tool. Output Current Test TEST PROCEDURE 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 3379 Fig 6 Alternator Current Output Test Fig 7 Alternator Current Output Test 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead of a suitable voltmeter to "B+" terminal of alternator, then connect negative lead to suitable ground. 5. Connect a suitable engine tachometer, then reconnect battery ground cable. 6. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon pile is in Open or Off position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 3380 7. Remove air hose between Engine Controller and air cleaner. Fig. 4 Alternator Connections (Plug Type) Fig. 5 Alternator Connections (Nut Type) 8. Connect suitable jumper wire to ground and K20 (field driver) terminal, at rear of alternator. This may generate a fault code. Do not connect power field circuit to ground, as component damage will occur. 9. Start engine and operate at idle speed, then adjust carbon pile and engine speed in increments until a speed of 1250 RPM at 15 volts is obtained. Do not allow voltmeter range to exceed 16 volts during inspection. TEST RESULTS 1. Note ammeter reading. 2. If reading is less than specified and alternator wire resistance is not excessive, alternator is defective. 3. After completion of current output inspection, turn off carbon pile and ignition switch, then disconnect battery ground cable. 4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "B+" lead to alternator output terminal. 5. Disconnect jumper wire, then connect air hose from Engine Controller to air cleaner. 6. Connect battery ground cable. 7. On models quipped with on board diagnostics, erase codes using DRB test tool or equivalent scan tool. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 3381 Alternator: Service and Repair 1. Disconnect battery ground cable, then remove belt. 2. Remove pivot and mounting bolts, then position alternator for wire connection access. 3. Remove harness hold-down, battery terminal, ground terminal and two field terminal nuts. 4. Remove wire connectors, then remove alternator. 5. Reverse procedure to install, noting the following: a. Torque mounting and pivot bolts to 30 ft. lbs. b. On models equipped with serpentine belts, the belt must be routed correctly or water pump will rotate in wrong direction and engine will overheat. See Serpentine Drive Belt in Engine/ Drive Belts..... Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 Amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay If the vehicle is equipped with a manual transmission circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the Controller Antilock Brakes (CAB). In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14 and G5. Each circuit is protected by a separate fuse. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 3389 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower steering column covers. Fig. 7 Ignition Switch Removal 4. Remove ignition switch mounting screws. Note the following: ^ Snap On torx tool No. TTXR20A2, or equivalent, is required. 5. Gently pull switch away from column and release two connector locks on seven pin terminal wiring connector, then remove connector from ignition switch. 6. Release connector lock on key-in-switch and Halo light four pin terminal connector. 7. Remove key cylinder from ignition switch as follows: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 3390 Fig. 8 Key Cylinder retainer Fig. 9 Unseated Key Cylinder a. Insert key and place ignition switch in Lock position. Use a small screwdriver to press key cylinder retaining pin flush with surface. b. Rotate key clockwise to Off position and unseat key cylinder from ignition switch assembly. c. Rotate key cylinder counterclockwise to Lock position and remove key. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 3391 Fig. 10 Key Cylinder Removal d. Remove key lock cylinder. INSTALLATION 1. Connect wiring connectors to switch ensuring lock tabs are fully seated. Fig. 11 Ignition Switch Column Lock Ring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 3392 Fig. 12 Ignition Switch Mounting Pad 2. Mount ignition switch to column. If equipped with column shift, shifter must be in Park position and park dowel pin on ignition switch must engage with column park lock slider linkage. Fig. 11 Ignition Switch Column Lock Ring 3. To verify ignition switch is in Lock position, flag should be parallel with ignition switch terminals. 4. Apply a small amount of grease to flag and pin, then position park-lock link and slider to mid-travel. 5. Position ignition switch against lock housing face, ensuring pin is inserted into park-lock link contour slot. Torque retaining screws to 17 inch lbs. 6. Install cover to column. Torque retaining screws to 17 inch lbs. 7. On models with tilt column,install tilt lever. 8. Connect ground cable to battery. 9. With key cylinder and ignition in Lock position, insert key cylinder into assembly until it bottoms. 10. Insert key, then push key cylinder inward and rotate key cylinder clockwise to end of travel. 11. Ensure proper operation of all switch and lock functions. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 3396 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 3397 Neutral Safety Switch: Description and Operation When closed, the case-grounded PARK/NEUTRAL position switch provides a ground path on circuit T41 for the coil side of the starter motor relay. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The PARK/NEUTRAL position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 3398 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 3399 Neutral Safety Switch: Service and Repair 1. Raise and support vehicle, then position drain pan under switch. 2. Disconnect switch wires and remove switch from case. 3. Ensure switch operating lever fingers center in case opening for switch when shift lever is in Park and Neutral positions. 4. Install switch and new seal. Torque switch to 25 ft. lbs. 5. Connect switch wires, lower vehicle and check transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor: Specifications Make .................................................................................................................................................... ............................................................. Nippondenso ID. No. ............................................................. .............................................................................................................................................................. ...... -- Type .......................................................................................................................................... .................................................................... Gear Reduction Power Rating, Kw ................................. .............................................................................................................................................................. .............. 1.4 Free Speed Test Amps [01] ............................................................................................................................................ .................................................................... 73 Volts ........................................................................... .............................................................................................................................................. 11 RPM [02] ....................................................................................................................................................... ...................................................... 3601 Cranking Amp Draw Test [03] ............................................................................................................. .................................................................... 150-220 Footnotes: [01] -- Maximum. [02] -- Minimum. [03] -- With engine at operating temperature. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 3403 Starter Motor: Application and ID Make .................................................................................................................................................... ............................................................. Nippondenso ID. No. ............................................................. .............................................................................................................................................................. ...... -- Type .......................................................................................................................................... .................................................................... Gear Reduction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 3404 Starter Motor: Description and Operation The Nippondenso starters are reduction gear field coil units; Bosch permanent magnet reduction gear starters contain a planetary gear train which transmits power between the starter motor and its pinion shaft. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting Starter Motor: Testing and Inspection Troubleshooting Fig 1 Starter Motor Troubleshooting Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 3407 Fig 2 Starting System Components Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 3408 Starter Motor: Testing and Inspection Diagnosis and Testing Starter Feed Circuit Tests 1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. Connect volt/ampere tester to battery terminals. Refer to operating instructions provided with tester being used. 3. Verify that all lights and accessories are Off and transmission shift selector is in Park for automatic transmissions/transaxles or Neutral for manual transmissions/transaxles, then set parking brake. 4. Hold ignition switch in Start position. Observe tester. a. If voltage reads above 9.6 volts and amperage draw reads above 250 amps, proceed to starter feed circuit resistance test. b. If voltage reads 12.4 volts or greater and amperage reads 0-10 amps, proceed to starter control circuit test. c. If starter motor turns engine freely at times, but starting system is still suspected, engage starter several times while observing tester. A starting system that has a problem should fail while performing this procedure. 5. After starting system problem have been corrected, verify battery state of charge, disconnect all testing equipment and connect distributor. Starter Feed Circuit Resistance Test The following test will require a voltmeter accurate to 0.1 volt. 1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. With all wiring harness and components connected properly, perform the following: a. Connect positive lead of voltmeter to battery negative post, and negative lead to battery negative cable clamp. Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable clamp and post. b. Connect positive lead of voltmeter to battery positive post, and negative lead to battery cable positive clamp. Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable clamp and post. c. Connect positive lead of voltmeter to battery negative terminal, and negative led to engine block near battery cable attaching point. 3. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor contact at ground cable attaching point. If reading is still above 0.2 volt, replace ground cable. 4. Remove starter heat shield (if equipped), then perform the following: a. Connect positive voltmeter lead to starter motor housing and negative lead to battery negative terminal. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor starter to engine ground. b. Connect positive voltmeter lead to positive battery terminal and negative lead to battery cable terminal on starter solenoid. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt, replace positive battery cable. 5. If resistance tests detect no feed circuit failures, remove starter motor and proceed to "Starter Solenoid Bench Test." Starter Control Circuit Test Notes The starter control circuit consists of a starter solenoid, starter relay, ignition switch and clutch pedal interlock switch (manual transmission) or neutral safety switch (automatic transmission). Disable ignition system on gasoline engines or fuel system on diesel engines prior to performing test procedures. Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still does not crank properly, repair or replace starter as necessary. Starter Relay Test Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 3409 Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Clutch Pedal Switch The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Starter Solenoid Bench Test Fig 6 Bosch Starter Solenoid Terminal Identification Fig 7 Nippondenso Starter Solenoid Terminal Identification 1. Remove starter assembly from vehicle. 2. Disconnect field coil wire from field coil terminal. 3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 3410 4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. 5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 3411 Starter Motor: Service and Repair 1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove lower mounting nut and lock washer, then remover upper mounting bolt. 3. Move starter forward until gears clears bellhousing, then tilt starter nose down past exhaust pipe. 4. Remove battery and solenoid wires, then remove starter. 5. Reverse procedure to install, noting the following: a. Torque starter mounting bolts to 50 ft. lbs. b. Torque starter mounting nuts to 20 ft. lbs. c. Torque battery lead terminal nut to 90 inch lbs. d. Torque solenoid lead terminal nut to 22 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3415 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3416 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3417 Starter Relay: Testing and Inspection Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Solenoid Test Starter Solenoid: Testing and Inspection Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still does not crank properly, repair or replace starter as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Solenoid Test > Page 3422 Starter Solenoid: Testing and Inspection Starter Solenoid Bench Test Fig 6 Bosch Starter Solenoid Terminal Identification Fig 7 Nippondenso Starter Solenoid Terminal Identification 1. Remove starter assembly from vehicle. 2. Disconnect field coil wire from field coil terminal. 3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist. 4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. 5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 Power Distribution Center: Connector Views Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Power Distribution (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Power Distribution (Part 2 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 Power Distribution (Part 3 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Power Distribution (Part 4 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 Power Distribution (Part 5 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 Power Distribution (Part 6 Of 6) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Ground Distribution (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Ground Distribution (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Ground Distribution (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Ground Distribution (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Ground Distribution (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Ground Distribution (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3462 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Fuse: Connector Views Fuse/Fuse Block Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Fuse panel is located under left side of instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3528 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3529 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3533 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3534 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Power Distribution Center: Connector Views Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Power Distribution (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Power Distribution (Part 2 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Power Distribution (Part 3 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Power Distribution (Part 4 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 Power Distribution (Part 5 Of 6) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 Power Distribution (Part 6 Of 6) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Ground Distribution (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Ground Distribution (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Ground Distribution (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 Ground Distribution (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 Ground Distribution (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Ground Distribution (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3574 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 Fuse: Connector Views Fuse/Fuse Block Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Fuse panel is located under left side of instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Fuse/Fuse Block (Part 2 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Fuse/Fuse Block (Part 3 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Fuse/Fuse Block (Part 4 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Fuse/Fuse Block (Part 5 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 Fuse/Fuse Block (Part 6 Of 7) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3640 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3641 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations The relay center is located on the lefthand side inner fender of the engine compartment, above the wheel house. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3645 Relay Box: Diagrams Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3646 Power Distribution (Part 2 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications Caster Angle, Degrees Limits ................................................................................................................................................... .............................................. +1/2 to +2 1/2 [01] Desired ................................................................... .................................................................................................................................................. +1 1/2 Camber Angle, Degrees Limits ................................................................................................................................................... ................................................................... 0 to +1 Desired ................................................................ ....................................................................................................................................................... + 1/2 Toe-In, Inch ......................................................................................................................................... .......................................................................... + 1/8 Ball Joint Wear, Inch ....................................... ...................................................................................................................................................... 0.020 [02] [01] -- Maximum left to right differential should not exceed +1 1/4. [02] -- For inspection procedure, refer to Ball Joint Inspection @ Steering & Suspension/ Suspension/ Ball Joint/ Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 3651 Alignment: Service and Repair CASTER & CAMBER 1. Remove all foreign material from exposed threads of pivot bar adjusting nuts. Fig. 1 Loosening Pivot Bar Adjusting Nuts 2. Record initial camber and caster readings before loosening pivot bar adjusting nuts. 3. Moving only rear pivot of upper control arm in or out will greatly affect caster while changing camber only slightly. Moving front pivot of upper control arm in or out will greatly affect camber while changing caster only slightly. 4. Caster should be held as nearly equal as possible on both wheels. 5. Camber settings should be held as close as possible to desired specifications. 6. After adjusting, torque tighten pivot bar attaching nuts to 155 ft. lbs. TOE-IN 1. Start engine, turn wheels both ways before straightening, then secure steering wheel with wheels pointed straight ahead. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 3652 Fig. 2 Toe Adjustment. 2WD Models Fig. 3 Toe Adjustment 4WD Models 2. Loosen tire rod adjustment sleeve camp bolts or nut. 3. Adjust toe-in by turning sleeves. Each wheel should be adjusted 1/2 total specification to ensure steering wheel being centered. 4. Torque locknut to 55 ft. lbs. or clamp bolts to 17 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 3663 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 3664 Front Steering Knuckle: Service and Repair 1. Raise and support vehicle, then place jack under outer end of lower control arm. 2. Remove wheel and tire, then remove brake caliper and support aside. CAUTION: Do not allow caliper to hang or be supported by hydraulic brake hose. 3. Disconnect tie rod end at steering knuckle arm, then remove ABS sensor wire, rotor dust shield and ABS pick-up from knuckle. 4. Remove upper and lower ball joint cotter pins and nuts, then use ball joint removal tool No. C-3564-A, or equivalent, to free upper and lower ball joints. 5. Remove tool and steering knuckle. 6. Remove splash shield and steering knuckle arm from steering knuckle. 7. Reverse procedure to install. Tighten bolts and nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair 1. With fluid at room temperature, ensure reservoir is at correct level. 2. Allow fluid to settle for a minimum of two minutes. 3. Start and run engine for a few minutes. 4. Add fluid as necessary, then repeat above steps until fluid level is constant. 5. Raise front wheels off ground. 6. Start engine, then slowly turn steering wheel left and right. Lightly contacting stops. 7. Stop engine and check fluid level, fill as necessary. 8. If fluid is extremely foamy, let stand for a few minutes, then repeat procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3673 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3674 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3675 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3680 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3681 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 3682 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir Power Steering Pump: Description and Operation Vane Type Power Steering Pump W/Integral Reservoir DESCRIPTION The hydraulic pump is a submerged, vane-type design. Submerged pumps have a housing and internal parts inside the reservoir and operate submerged in fluid. OPERATION There are two openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly and the end plate. The smaller opening contains the pressure line union, flow control valve, and spring. The flow control orifice is part of the pressure line union. The pressure relief valve, located inside the flow control valve, limits pump pressure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir > Page 3685 Power Steering Pump: Description and Operation Vane Type Power Steering Pump Less Integral Reservoir DESCRIPTION The hydraulic pump is a non-submerged vane-type design. The housing and internal parts are separate from the reservoir and are not submerged in fluid. OPERATION There are two bore openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening contains the pressure line union, flow control valve and spring. The pressure relief valve inside the flow control valve limits pump pressure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play Power Steering Pump: Testing and Inspection Excessive Steering Wheel Play 1. Excessive play in steering gearbox. 2. Loose steering gear. 3. Loose or worn tie rod end stud. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 3688 Power Steering Pump: Testing and Inspection Hard Steering Wheel Operation 1. Air in fluid line. 2. Loose or damaged belt. 3. Low or leaking fluid. 4. Twisted or damaged power steering hoses. 5. Gearbox or pump malfunction. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 3689 Power Steering Pump: Testing and Inspection Noisy Operation 1. Loose oil pump or gearbox. 2. Loose pulley nut. 3. Interference between pressure hose and other parts. 4. Air entering oil pump. 5. Pump seizure. 6. Loose belt. 7. Gearbox port section damage. 8. Return hose malfunction. 9. Loose oil pump or pump bracket. 10. Excessive oil pump body wear. 11. Malfunctioning steering stopper. 12. Wheel and tire to body interference. 13. Malfunctioning gearbox. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 3690 Power Steering Pump: Testing and Inspection Oil Leaks Pump Oil Leak Checking. Saginaw Submerged Vane Pump W/intregal Reservoir (P Type) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 3691 Pump Oil Leak Checking. Saginaw Vane Pump W/external Reservoir (TC Type) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul Power Steering Pump: Service and Repair Power Steering Pump Overhaul Vane Type Power Steering Pump w/ Integral Reservoir Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3694 DISASSEMBLE NOTE: Before disassembly of pump, remove filler cap and drain fluid. If broken components or foreign materials are found during disassembly, hydraulic system should be disassembled, inspected, cleaned and flushed before servicing is complete. 1. Clean exterior of pump with solvent and crocus cloth. 2. Remove bolt and fitting from rear of pump reservoir, then the reservoir and seals. 3. Remove end plate retaining ring using a screwdriver and punch. 4. Remove endplate and pressure plate spring, then the O-ring, control valve and control valve spring by inverting housing. 5. Tap lightly on driveshaft with a rubber mallet to remove pressure plate. 6. Pull out pump ring and vanes, then remove shaft retaining ring, pump rotor and thrust plate. 7. Remove driveshaft key from slot in shaft, then with end of shaft pointed downward, press down until shaft is free. 8. Remove seals, dowel pins and O-rings. INSPECTION 1. Clean all parts with solvent and blow dry. 2. Check vane tips for scoring or wear. Vanes must fit snugly but slide freely in slots of rotor. Examine rotor slots for burrs and excessive wear at thrust faces. 3. Check inner surface of pump ring for scoring or wear and thrust plate and pressure plate for wear on plate surfaces. 4. If heavy wear is evident in any of above components, replace entire rotating group. 5. Inspect seal for leakage, cracking or swelling, if evident replace seal. 6. Check driveshaft for excessive burning or scoring. 7. Control valve must move smoothly in the valve bore. ASSEMBLE 1. Lubricate O-rings, pump ring, rotor and vanes with power steering fluid. 2. Install O-rings and dowel pins on pump housing. 3. Using a seal installation tool, insert seal into front of housing. 4. Install driveshaft and thrust plate. Ensure counterbore faces driveshaft end of housing and install rotor. 5. Insert vanes into rotor, ensuring rounded edge faces away from rotor. 6. Install shaft retaining ring, pump ring and pressure plate. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3695 7. Insert control valve spring, then install control valve and O-ring. 8. Install pressure plate spring and end plate, then secure with end plate retaining ring. 9. Connect seal and reservoir, then install bolt and fitting TC Series DISASSEMBLE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3696 Prior to disassembly of the pump, remove filler cap and drain fluid. If broken components or foreign materials are found during disassembly, then the hydraulic system should be disassembled, inspected, cleaned and flushed before service is complete. 1. Clean exterior of pump with solvent, then clamp front hub of pump into a soft jaw vise. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3697 2. Pry tab and slide retaining clip off of pump. 3. Remove reservoir, then return tube as follows: a. Install five 5/8 inch washers and a 9/16-12 nut outside of tube. b. Plug tube to prevent chips from entering, then insert a 9/16-12 tap into return tube and turn until tube is pulled out of housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3698 4. Remove O-ring, fitting, O-ring seal, flow control valve and spring. 5. Using snap ring pliers, remove retaining ring. Note position of large lug in housing before removal. 6. Remove driveshaft and bearing. Note and measure any clearance between collar and shaft. Press bearing from shaft using a support ring under bearing. 7. Remove driveshaft seal by prying seal loose with a screwdriver. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3699 8. Insert a punch into access hole, then pry retaining ring loose with a screwdriver. 9. Using a 5/16 inch piece of bar stock or a suitable brass drift, remove thrust plate. 10. Remove pump ring, rotor, vanes and dowel pins. 11. Remove pressure plate and O-ring, then the spring, seal and remaining dowel pin. 12. Using a suitable punch, remove sleeve assembly. INSPECTION 1. Clean all parts with solvent and blow dry. 2. Inspect rotating components as follows: a. Vane tips for scoring or wear. b. Fit of vanes in rotor. Vanes must fit properly in slots without sticking or excessive play. c. Rotor slots for burrs and excessive wear at thrust faces. d. Inner surface of pump ring for scoring or wear. e. Thrust plate and pressure plate for wear on plate surfaces. f. If heavy wear is present, or parts are faulty, replace entire rotating group. 3. Inspect bearing for rough or looseness and bearing seal for leakage, cracking or swelling. 4. Check driveshaft and bearing bore for excessive burning or scoring. 5. Control valve must move smoothly in the valve bore. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3700 ASSEMBLE 1. Press sleeve into housing using a suitable socket and press. 2. Install dowel pin, seal and pressure plate spring. 3. Install O-ring seal, pressure plate and dowel pins. Mark top of pressure plate where pin enters from underneath to ease alignment with dowel pin during assembly. 4. Lubricate O-ring, pump ring, rotor and vanes with power steering fluid. Install vanes and rotor with rounded edge facing away from rotor. Ensure counterbore of rotor faces driveshaft end of housing. 5. Install pump ring with identification marks facing up, then install O-ring seal and thrust plate. Thrust plate dimples must line up with bolt holes in housing and plate must engage pump ring dowel pins. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3701 6. Using a press to compress thrust plate, install retaining plate with the center opening of ring with bolt hole nearest the access hole. 7. Using a suitable socket and press, install driveshaft seal into housing until it bottoms. 8. Install bearing onto driveshaft, then slide assembly into housing while rotating driveshaft so shaft serrations engage with rotor. 9. Insert retaining ring ensuring large tab of ring is properly located. Refer to. 10. Install flow control spring, control valve, O-ring seal and O-ring. 11. Install reservoir or return tube, then clips if equipped. CB Series DISASSEMBLE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3702 Exploded View Of CB Series Power Steering Pump 1. Remove reservoir retaining clips from reservoir assembly and housing. 2. Separate reservoir from housing, then remove O-ring from reservoir. 3. Remove O-ring union fitting and O-ring. 4. Remove control valve assembly and flow control spring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3703 5. Protect drive shaft with shim stock. 6. Using a small chisel, cut drive shaft seal. 7. Remove drive shaft seal from housing. 8. Insert a small punch through access hole in housing, then remove retaining ring from housing. 9. Remove pump internal components by gently pushing on drive shaft. 10. Remove O-ring from pump housing. 11. Remove dowel pins, end cover, pressure plate spring and O-ring from pressure plate. 12. Remove pump ring and vanes from drive shaft subassembly. 13. Remove shaft retaining ring from drive shaft. 14. Remove pump rotor and thrust plate from drive shaft. INSPECTION 1. Check the following parts for any scoring, pitting or chatter marks: a. Pressure plate. b. Pump ring. c. Rotor. d. Vanes. e. Thrust plate. f. Drive shaft. 2. Replace any parts with any signs of excessive wear or damage. ASSEMBLE 1. Clean all parts in power steering fluid, then thoroughly dry all parts. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3704 2. Lubricate new drive shaft seal with power steering fluid, then install seal into pump housing using suitable seal installation tool or socket. 3. Install pump ring dowel pins into pump housing. 4. Install thrust plate, pump rotor and new shaft retaining ring onto drive shaft. 5. Install drive shaft subassembly into pump housing. 6. Install vanes into pump rotor. 7. Install pump ring onto dowel pins. 8. Lubricate new oil ring with power steering fluid, then install O-ring into end cover. 9. Lubricate outer edge of end cover with power steering fluid, then press end cover into pump housing. 10. Insert O-ring into groove in pump housing with ring opening near access hole in pump housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3705 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation 1. Remove serpentine drive belt, then clamp return hose, remove and cap hoses and fittings. 2. Remove battery ground cable, then remove bracket bolts. 3. Remove pump pulley, pump attaching screws and pump. 4. Reverse procedure to install. Tighten bolts and screws to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation CIRCUIT OPERATION When the power steering pressure switch close, it connects circuit K10 from the Powertrain Control Module (PCM) to ground on circuit Z1. In response the PCM increases idle speed for additional add power steering assist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 3715 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications Steering Gear: Mechanical Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. Adjustment Cap Locknut ..................................................................................................................... ............................................................................... 80 Adjustment Screw Locknut ............................. .............................................................................................................................................................. ..... 20 Gear to Frame Bolts ................................................................................................................. .......................................................................................... 70 High Pressure Fluid Line ..................... .............................................................................................................................................................. ................. 25 Intermediate Shaft Pinch Bolts ..................................................................................... ...................................................................................................... 35 Pitman Shaft Nut ..................... .............................................................................................................................................................. ........................... 185 Rack-Piston Plug .............................................................................................. .................................................................................................................. 75 Return Pressure Fluid Line ...................................................................................................................................................... ........................................... 25 Return Guide Clamp Bolt .................................................................... ...................................................................................................................... 48 [04] Side Cover Bolts .............................................................................................................................................................. .................................................. 45 Footnotes: [04] -- inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 3720 Steering Gear: Pressure, Vacuum and Temperature Specifications Power Steering Pressure Specifications Initial Pressure, psi .............................................................................................................................. .......................................................................... 50-80 Maximum Pressure, psi .................................. .............................................................................................................................................................. ......... - Relief Pressure, psi ................................................................................................................. ........................................................................................ 1450 Power Steering Flow Rate Specifications Flow Rate, psi ...................................................................................................................................... ......................................................................... 50-80 Flow Rate, GPM .............................................. ........................................................................................................................................................... 1.3-1.9 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 3721 Steering Gear: Application and ID Steering Gear ...................................................................................................................................... .................................................. TRW Rack & Pinion Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 3722 Steering Gear: Description and Operation Rack & Pinion Steering Gear DESCRIPTION The Dakota manual steering gear assembly consists of a housing which contains a toothed rack, a pinion, rack slipper and rack slipper spring. OPERATION The steering gear rack and pinion assembly converts rotational movement of the pinion assembly into transverse movement of the rack. Tie rods and tie rod ends transmit this movement to the steering arms and wheels while accommodating suspension movement at the same time. The tie rods are coupled to the ends of the rack. This connection is protected by a bellows type oil seal which retains steering gear lubricant. The pinion runs on straddle mounted ball bearings. The lower bearing is incorporated in the pinion housing. The upper bearing is swagged to the pinion shaft. Lock to lock stops are built into the steering gear. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Wheel Binds Steering Gear: Testing and Inspection Steering Wheel Binds 1. Low fluid level. 2. Tires improperly inflated. 3. Lack of lube in ball joints or outer tie rod ends. 4. Loose pump belt. 5. Faulty pump flow. 6. Excessive friction in steering column or intermediate shaft. 7. Steering column coupling binding. 8. Excessive friction in gear. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Wheel Binds > Page 3725 Steering Gear: Testing and Inspection Steering Wheel Shudder 1. Air in power steering system. 2. Tires improperly inflated. 3. Excessive engine vibration. 4. Faulty accessory drive belt tensioner. 5. Overcharged air conditioning system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Wheel Binds > Page 3726 Steering Gear: Testing and Inspection Hard Steering 1. Tires improperly inflated. 2. Low fluid level. 3. Loose belt. 4. Lack of ball joint lubrication. 5. Low pump pressure. 6. High internal gear leak. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Wheel Binds > Page 3727 Steering Gear: Testing and Inspection Poor Return to Center 1. Tires improperly inflated. 2. Improper front wheel alignment. 3. Lack of lubrication in ball joint. 4. Steering column U-joints misaligned. 5. Improperly positioned dash cover. 6. Steering wheel rubbing. 7. Tight steering shaft bearings. 8. Excessive friction coupling universal joint. 9. High friction in steering gear. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 3728 Steering Gear: Adjustments The steering gear cannot be adjusted or repaired. If a malfunction occurs, the entire rack and pinion assembly must be replaced. If bellows seal is leaking or damaged, remove gear from vehicle. Drain, clean and lubricate gear with 1/4 pint of MS-5644 (90 weight) hypoid oil. Replace damaged or leaking bellows. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear Service Steering Gear: Service and Repair Power Steering Gear Service This steering gear is not repairable. If a problem is indicated, the unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear Service > Page 3731 Steering Gear: Service and Repair Steering Gear Replacement 1. Raise and support vehicle, then remove tie-rod ball joint cotter pins and nuts. 2. Use ball joint puller tool No. C-3894-A, or equivalent, to loosen tie-rod ball joints from steering knuckle. 3. Remove power steering tubes, then remove power steering pump hoses and disconnect steering shaft coupler from pinion gear by collapsing shaft. 4. Remove gear attaching bolts and gear. 5. Reverse procedure to install. Tighten attaching bolts to specification. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair CAUTION: Do not hammer, jolt or shock steering wheel or column during removal or installation. REMOVAL 1. Ensure front wheels are pointed straight ahead, then disconnect battery ground cable. 2. Remove speed control switch or trim piece mounting screws from underside of steering wheel, then pull switches from wheel and disconnect connectors. 3. Pry right rear steering wheel cover off, then remove four nuts attaching air bag module. 4. Remove air bag module and disconnect squib connector. 5. Remove steering wheel retaining nut and remove steering wheel from shaft with a steering wheel puller. Steering wheel and shaft are master splined for installation reference. INSTALLATION 1. Pull speed control and air bag wires through lower steering wheel hole, then pull horn wire through smaller hole at top of wheel. Ensure wires are not pinched. 2. Install retaining nut. Force steering wheel down with retaining nut only. Torque to 45 ft lbs. 3. Connect horn button, speed control switch and air bag module wires, then connect clockspring wiring connector. Ensure connector latches securely beneath module locking clip. 4. Mount air bag module on steering wheel. Torque four nuts to 80-100 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair Tie Rod End: Service and Repair Chrysler does not provide a procedure to service the inner tie rod end separately from the rack and pinion assembly. The rack and pinion is serviced as a complete unit only. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint 1. Raise front of vehicle and support both lower suspension arms with safety stands. Place stands as far outboard as possible. Upper arms must not contact rebound bumpers. 2. Clamp dial indicator to lower suspension arm, position plunger against knuckle arm and zero indicator. 3. Pry tire/wheel up and down and measure knuckle's axial movement with respect to suspension arm. Replace ball joint if travel is 0.020 inch or more. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 3744 Ball Joint: Testing and Inspection Upper Ball Joint Jack lower suspension up enough to lift weight off wheel but still maintain slight tire contact with ground. Force top of tire in and out. Replace ball joint if there is any lateral movement between upper suspension arm and steering knuckle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement Removal 1. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove disc brake caliper from steering knuckle and rotor. 4. Remove shock absorber. 5. Install Spring Compressor DD-1278. Use a piece of pipe to fabricate a spacer positioned between the tool and suspension arm. 6. Tighten tool nut against bell-shaped adapter tool finger-tight and loosen 1/2 of-a-turn. 7. Remove cotter pins and nuts from ball studs. 8. Position Ball Stud Remover C-3564A as shown. Rotate threaded portion of tool to apply force to the lower ball stud. 9. Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. Lower Ball Stud Removal 10. Remove ball stud seal. Use Remover/Installer C-4212 to press the ball stud from lower suspension arm bore. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 3747 Installation Lower Ball Stud Installation 1. Press new ball stud in lower suspension arm with Remover/Installer C-4212. 2. Position new seal over ball stud. Use a socket to force retaining lip of seal until securely locked in place. 3. Position steering knuckle on ball studs. Install ball stud retaining nuts. Tighten lower nut to 183 N.m (135 ft. lbs.). Tighten upper nut to 142 N.m (105 ft. lbs.) and install new cotter pins. 4. Remove spring compressor tool and install shock absorber. 5. Install the disc brake caliper. 6. Install the wheel and tire assembly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 3748 Ball Joint: Service and Repair Upper Ball Joint Replacement 1. With jack under lower suspension arm outer end, raise and support vehicle, then remove wheel and tire. 2. Remove upper ball joint cotter pin and nut. 3. Apply force to upper ball joint with ball joint removal tool No. C-3564-A, or equivalent, then strike steering knuckle sharply with hammer to loosen joint from knuckle. Do not force joint out of knuckle with tool. 4. Removal ball stud seal, then use ball joint removal/installation tool No. C-3561, or equivalent, to unscrew ball joint from control arm 5. Reverse procedure to install, using new seal. Ball joint and suspension arm bore gap should be 0.01 to 0.05 inch. Tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 3753 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 3754 Front Steering Knuckle: Service and Repair 1. Raise and support vehicle, then place jack under outer end of lower control arm. 2. Remove wheel and tire, then remove brake caliper and support aside. CAUTION: Do not allow caliper to hang or be supported by hydraulic brake hose. 3. Disconnect tie rod end at steering knuckle arm, then remove ABS sensor wire, rotor dust shield and ABS pick-up from knuckle. 4. Remove upper and lower ball joint cotter pins and nuts, then use ball joint removal tool No. C-3564-A, or equivalent, to free upper and lower ball joints. 5. Remove tool and steering knuckle. 6. Remove splash shield and steering knuckle arm from steering knuckle. 7. Reverse procedure to install. Tighten bolts and nuts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair Stabilizer Bar: Service and Repair 1. Raise and support vehicle, then remove stabilizer bar link anchor bolt's nut and washer at lower suspension arm on each side. 2. Remove link bolt, retainers, insulators and spacers from each control arm. 3. Remove retainer bolts, retainer and stabilizer bar. 4. Reverse procedure to install ensuring alignment, frame clearance and equal spacing on each side. Tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs Suspension Spring ( Coil / Leaf ): Service and Repair Coil Springs 1. Raise and support vehicle, then remove wheel and tire. 2. Disconnect stabilizer bar from control arm and remove shock absorber. 3. Install spring compressor tool No. DD-1278, or equivalent, through lower suspension arm and coil spring, then tighten tool nut and compress spring. 4. Place two jack stands under the lower suspension arm immediately outward from where the bushings are located. Adjust the jack stands against the lower suspension arm. 5. Relieve coil spring tension by slowly lowering jackstands, then remove tool, coil spring and isolator pad. 6. Reverse procedure to install. Tighten control arm front and rear retaining nut to specification. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 3762 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement 1. Raise and support rear of vehicle with jack or hoist only. Lift point is under frame rail crossmember after of rear axle. Be careful not to bend side rail flange. 2. Use jack to lift axle weight from springs, then remove wheel. 3. Remove nuts, U-bolts and spring bracket from axle then remove spring rear eye shackle nut and bolt. 4. Remove spring from vehicle. 5. Reverse procedure to install ensuring spring center bolt is in rear axle pad locating hole. Install U-bolt nuts, spring eye pivot bolt and shackle nuts finger tight, then tighten to specifications after vehicle is lowered to ground. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair Suspension Strut / Shock Absorber: Service and Repair 1. Raise and support vehicle, then remove lower shock absorber nut and bolt from axle bracket. 2. Remove upper shock absorber nuts and bolts from frame crossmember bracket. 3. Remove lower attaching nut at bushing end. 4. Remove shock absorber from vehicle. 5. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments 1. Tighten adjusting nut to specifications while rotating hub. 2. Stop rotation and loosen adjusting nut, then tighten nut finger tight and install locknut and new cotter pin. 3. Endplay should be: 0.000-0.003 inch on 1995 models. 0.001-0.003 inch on 1996 models. 4. Clean grease cap, coat (do not fill) inside with wheel bearing grease and install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Locations Fig. 2 Dakota Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Tires: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments 1. Tighten adjusting nut to specifications while rotating hub. 2. Stop rotation and loosen adjusting nut, then tighten nut finger tight and install locknut and new cotter pin. 3. Endplay should be: 0.000-0.003 inch on 1995 models. 0.001-0.003 inch on 1996 models. 4. Clean grease cap, coat (do not fill) inside with wheel bearing grease and install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 3788 Blower Motor: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, circuit A2 from fuse E in the Power Distribution Center (PDC) connects with circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block that powers fuse 1. Fuse 1 protects circuit C1 which supplies battery voltage to the blower motor. The ground path for the blower motor is through circuit H6 to the blower motor resistor block and then through the fan switch in the A/C heater controls to circuit Z1. The blower motor resistor block consists of four resistors connected in series. Each resistor in the blower motor resistor block is spliced to the fan switch on separate circuits; C4, C5, C6, and C7. Depending on fan switch position, voltage passes through one or more resistors to ground. Blower motor fan speed is controlled by the number of resistors voltage passes through to ground. When the fan switch is in the LOW position, circuit C4 provides the ground path. In the M1 position, circuit C5 provides ground. In the M2 position, the ground path is through circuit C6. Circuit C7 provides path for ground when the switch is in the HIGH position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 3789 Blower Motor: Service and Repair BLOWER MOTOR AND WHEEL ASSEMBLY- REMOVAL/INSTALLATION (1) Disconnect the negative battery cable. (2) Remove the lower instrument panel module (refer Instrument Panel gauges, and warning indicators). (3) On vehicles equipped with A/C disconnect the 2 vacuum lines from the recirculating air door actuator. Disconnect blower lead wire connector. (4) Remove 2 screws at the top of the blower housing, securing it to the unit cover. (5) Remove 5 screws from round the blower housing and separate the blower housing from the unit. Blower Housing (Typical) (6) Remove 3 screws, securing the blower and wheel assembly to the heater or A/C unit housing and separate the assembly from the unit. To install, reverse the preceding operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 3790 BLOWER MOTOR AND WHEEL SUBASSEMBLY-REMOVAL/INSTALLATION (1) Using a pair of common pliers, remove the spring type retaining ring from the center of the blower wheel. (2) Slip blower wheel from blower motor shaft. To install, reverse the preceding operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Description and Operation Compressor HVAC: Description and Operation CIRCUIT OPERATION When the A/C-heater control switch is moved to an A/C position or the defrost position, and the A/C high pressure and low pressure switches close, the Powertrain Control Module (PCM) receives an A/C request signal on circuit C20. Circuit C20 connects to cavity C22 of the PCM. After receiving the A/C request signal, the PCM supplies ground for the coil side of the A/C compressor clutch relay on circuit C13. Circuit C13 connects to cavity C1 of the PCM. Circuit A21 from the ignition switch supplies power for the coil sides of the relay Circuit C26 from fuse B in the Power Distribution Center (PDC) supplies voltage to the contact side of the relay. When the PCM grounds the A/C compressor clutch relay, the contacts close and connect circuits C26 and C3. Circuit C3 supplies voltage to the A/C compressor clutch. Ground for the compressor clutch is provided on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Description and Operation > Page 3794 Compressor HVAC: Testing and Inspection Circuit C90 from the A/C heater control switch connects to the low pressure switch. Circuit C22 from the low pressure switch connects to the high pressure switch. Circuit C20 from the high pressure switch connects to the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Description and Operation > Page 3795 Compressor HVAC: Service and Repair The compressor must be purged of air whenever it has been isolated from the system for service. 1. Install oil plugs or reconnect refrigerant lines and manual valves to compressor as needed. 2. Cap service access ports on both manual valves, then rotate low (suction) side service valve counterclockwise to the back-seated position. 3. Rotate high (discharge) side manual valve to mid-position, then slightly loosen cap on high side gauge port to allow refrigerant to force air out of compressor. 4. Back seat high side manual valve, then tighten gauge port cap. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 3807 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 3808 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 3814 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 3815 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3824 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3825 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3826 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3827 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3828 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3829 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3830 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3831 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3832 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3833 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3834 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3835 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3841 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3842 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3843 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3844 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3845 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3846 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3847 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3848 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3849 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3850 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3851 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 3852 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 3853 Evaporator Core: Service and Repair REMOVAL 1. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Place the unit on a work bench and remove the housing top cover. Evaporator Coil Remove/Install 3. Lift the evaporator coil from the housing. INSTALLATION 1. Position the evaporator coil in the heater-A/C housing. 2. Install the housing top cover. 3. Install the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations The fixed orifice tube is located in the outlet line of the condenser. It has filter screens on the inlet and outlet ends of the tube body. The filter screens act as a strainer for the liquid refrigerant flowing through the fixed orifice opening. 0-rings, on the tube body, prevent the high pressure liquid refrigerant from bypassing the orifice. Adjustments cannot be made to the fixed orifice tube. If it becomes clogged or damaged, replace the fixed orifice tube. The fixed orifice tube assembly is the restriction between the high and low pressure liquid refrigerant. It meters the flow of liquid refrigerant into the evaporator core. Minimum evaporator temperature is controlled by sensing the pressure within the evaporator with a pressure-operated electric cycling clutch switch. The pressure switch controls compressor operation as necessary to prevent evaporator freeze-up. The fixed orifice tube should be replaced whenever a compressor is replaced for lack of performance (internal damage). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair REMOVAL 1. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Place the unit on a work bench and remove the housing top cover. 3. Remove the attaching screw from the heater core retaining bracket and lift the heater core from the housing. INSTALLATION 1. Position the heater core in the heater-A/C housing. 2. Install and tighten the attaching screw to the heater core retaining bracket. 3. Install the housing top cover. 4. Install the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system as described in this group. 3. Remove the lower instrument panel module. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 4. Remove the air distribution duct. Secure Wiring Harness 5. Tape the wiring harness out of the way. 6. Remove the antenna coaxial cable from the retaining clip at the right end of the heater-A/C housing. 7. Unplug the blower motor wiring connector and remove the retainer from the support brace. 8. Disconnect the demister hoses from the adapter on the top of the heater-A/C housing. 9. Disconnect the main vacuum harness connector from the heater-A/C control vacuum harness connector. 10. Disconnect the temperature control cable flag retainer from the heater-A/C housing and remove the self-adjusting clip from the blend-air door crank. 11. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 12. Disconnect the refrigerant lines from the evaporator coil. Install plugs in, or tape over, all of the open refrigerant fittings. 13. Disconnect the heater hoses. Install plugs in the heater core tubes to prevent spilling engine coolant into the interior of the vehicle. Condensate Drain Tube Removal/Install 14. Remove the condensate drain tube. 15. Remove the four housing attaching nuts from the engine compartment side of the dash panel. 16. Remove the housing support brace mounting screw. Swing the support brace to the left, out of the way. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 3863 Drop Heater A/C Unit 17. Carefully pull the housing rearward until the mounting studs clear the dash panel. Then allow the unit to drop down. Rotate Heater A/C Unit 18. Rotate the heater-A/C housing until the mounting studs are facing downward. Then remove the unit from the vehicle. DISASSEMBLE Heater A/C Housing 1. Place the heater-A/C housing on a suitable work surface. 2. Locate and remove one retaining nut from the blend-air door pivot shaft. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 3864 Blend-Air Door Crank Arm Remove/Install (typical) 3. Using a pair of pliers, place one jaw on top of the pivot shaft and the other jaw under the crank linkage. Pinch the crank off of the pivot shaft. 4. Disconnect the vacuum lines from the mode door actuators and position them out of the way. 5. Remove the housing cover attaching screws. Heater A/C Housing Cover Remove/Install 6. Remove the cover from the housing. ASSEMBLE 1. Install the cover into place while guiding the mode door pivot shaft into its socket. 2. Install the cover attaching screws into the housing. 3. Connect the vacuum lines to the mode door actuators. 4. Install the crank onto the blend-air door pivot shaft. 5. Install the vacuum lines to the actuator. INSTALLATION 1. Place the unit in the vehicle with the mounting studs facing downward. Carefully rotate and push the housing forward until the mounting studs fit into the holes in the dash panel. 2. Install housing support brace and tighten the attaching screw. 3. Install and tighten the four housing mounting nuts on the engine compartment side of the dash panel. 4. Install the condensate drain tube. 5. Remove the plugs from the heater core tubes and connect the heater hoses. 6. Remove the plugs or tape from the refrigerant fittings and install the lines on the evaporator coil. 7. Install the temperature control cable self-adjusting clip to the blend-air door crank. Connect the temperature control cable flag retainer to the heater- A/C housing. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 3865 8. Connect the vacuum harness connectors from the housing and the heater-A/C control. 9. Connect the demister hoses to the adapter on the top of the heater-A/C housing. 10. Connect the blower motor wiring. 11. Install the antenna coaxial cable to the retaining clip at the right end of the housing. 12. Remove the tape holding the wiring harness out of the way. 13. Install the center air distribution duct. 14. Install the lower instrument panel module. Refer to Instrument Panel for the procedures. 15. Connect the battery negative cable. 16. Fill the engine cooling system. Refer to Cooling System for the procedures. 17. Evacuate and charge the refrigerant system. Refer to Heating and Air Conditioning. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Capacity 2.0 lb (US) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3870 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant type R134a Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications With Compressor Model, SD7H15 Component Oil Capacity ...................................................................................................................... .................................................................. Ounces Total Capacity ..................................................... ........................................................................................................................................................ 7.75 Compressor ......................................................................................................................................... ....................................................................... -- Condenser ................................................................ .................................................................................................................................................. 1 Evaporator ........................................................................................................................................... ....................................................................... 2 Filter-Drier ................................................................. ................................................................................................................................................ 4 Line .. .............................................................................................................................................................. ............................................................ -- Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Power Distribution (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 3884 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 3889 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 3890 Air Bag: Locations Airbag Module, Connector And Clockspring Squib Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 3891 Driver Squib Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information Air Bag: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 3894 Air Bag: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag Squib (Airbag Igniter) Air Bag: Description and Operation Air Bag Squib (Airbag Igniter) CIRCUIT OPERATION Two circuits, R43 and R45, connect the ACM to the driver's side airbag squib (igniter) after passing through the clock spring connector. R43 and R45 are a twisted pair of wires Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag Squib (Airbag Igniter) > Page 3897 Air Bag: Description and Operation Air Bag Module Operation DRIVER AIR BAG The driver air bag, located on steering wheel, contains air bag cushion and its supporting components. The driver inflator is mounted on back of module housing. When supplied with proper electrical signal inflator assembly will produce a gas and discharge it directly into cushion. A protective cover is fitted to front of driver air bag module. Description The airbag module protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the airbag module trim cover are the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Operation The inflator assembly is mounted to the back of the module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at the predetermined breakout line. PASSENGER AIR BAG The passenger air bag module is mounted to instrument panel retainer, knee bolster and glove compartment. The passenger inflator assembly is inside module housing. When supplied with proper electrical signal inflator will produce a gas and discharge it directly into cushion. A protective cover is fitted over air bag module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures Air Bag: Service and Repair Air Bag Module Disposal Procedures AIR BAG MODULE DISPOSAL After deployment, air bag module should be placed in a plastic bag and disposed of in same manner as any other scrap parts, except that following points should be carefully noted during disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be worn. 2. There may be material adhered to air bag module that could irritate eyes and/or skin. If any irritation develops, seek medical attention. Note following: a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of irritation continues, consult a physician. 3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4. Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5. Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle interior as follows: a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. 8. An air bag that has been deployed should be removed as outlined. 9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. 10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module, module must be deployed as follows: a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service, air bags must be removed and deployed outside vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3900 Air Bag: Service and Repair Airbag Deployment IN VEHICLE DEPLOYMENT 1. Disconnect battery ground cable. 2. Remove knee blocker. 3. Disconnect clockspring lead from base of steering column at instrument panel harness. 4. Cut connector off clockspring lead and strip one inch of insulation from end. 5. Make a harness consisting of two wires at least 20 ft. long. 6. Connect two wires at lower end of clockspring lead to new harness. 7. Making sure that no one is within 20 ft. of the vehicle, touch two new harness wire leads to terminals of a 12 volt car battery. WARNING: When deployment is achieved, there will be a loud bang and airbag will inflate. Wait at least 20 minutes before approaching vehicle. Let airbag cool off and dust settle. OUT OF VEHICLE DEPLOYMENT 1. Disconnect battery ground cable. 2. Remove airbag module from steering wheel. 3. Cut wiring harness that goes from clockspring to airbag as close to clockspring as possible. 4. Place other end of harness back into airbag module. 5. Strip one inch of insulation from cut end of harness and connect two 20 ft. wires. 6. Place airbag module face up and move at least 20 ft. away. 7. Touch two ends of 20 ft. long wires to terminals of a 12 volt battery. WARNING: When deployment is achieved, there will be a loud bang and airbag will inflate. Wait at least 20 minutes before approaching, let airbag cool off and dust settle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3901 Air Bag: Service and Repair Airbag Module Storage & Handling WARNING: Before attempting to diagnose, remove or install any airbag system components, unless otherwise noted, you must first disconnect and isolate battery ground cable. Failure to do so could result in accidental deployment and possible personal injury. STORAGE - The airbag module must be stored in its original special container until it is used. - It must be stored in a clean, dry place, away from heat, sparks and sources of electricity. - Always place or store the module on a surface with the trim cover facing up. HANDLING WARNINGS: - At no time should any source of electricity be permitted near the inflator on the back of the module. - When handling a live module, the trim cover should be pointed away from the body to minimize injury in the event of accidental deployment. - Always place or store the module on a surface with the trim cover facing up. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3902 Air Bag: Service and Repair Cleanup Procedure Wear Safety Glasses and Rubber Gloves - Typical WARNING: If you experience skin irritation during cleanup, run cool water over the affected area. also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Following an airbag system deployment, the vehicle interior will contain a powdery residue. This residue is primarily sodium bicarbonate (baking soda), used as an airbag cushion lubricant. However, there will also be traces of sodium hydroxide powder, a chemical by-product of the generant used for airbag deployment. Since this powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. Fig 3 Airbag Exhaust Vent Sealing Begin the cleanup by applying tape over the airbag exhaust vent so no more powder will be released into the vehicle. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on an uncleaned area. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3903 Vacuum Heater and A/C Outlets - Typical Be sure to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioning blower on the lowest speed setting and vacuum any powder expelled from the outlets. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Place the deployed airbag modules in your vehicular scrap pile. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3904 Air Bag: Service and Repair Air Bag Module Disposal Procedures AIR BAG MODULE DISPOSAL After deployment, air bag module should be placed in a plastic bag and disposed of in same manner as any other scrap parts, except that following points should be carefully noted during disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be worn. 2. There may be material adhered to air bag module that could irritate eyes and/or skin. If any irritation develops, seek medical attention. Note following: a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of irritation continues, consult a physician. 3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4. Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5. Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle interior as follows: a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. 8. An air bag that has been deployed should be removed as outlined. 9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. 10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module, module must be deployed as follows: a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service, air bags must be removed and deployed outside vehicle. Airbag Deployment IN VEHICLE DEPLOYMENT 1. Disconnect battery ground cable. 2. Remove knee blocker. 3. Disconnect clockspring lead from base of steering column at instrument panel harness. 4. Cut connector off clockspring lead and strip one inch of insulation from end. 5. Make a harness consisting of two wires at least 20 ft. long. 6. Connect two wires at lower end of clockspring lead to new harness. 7. Making sure that no one is within 20 ft. of the vehicle, touch two new harness wire leads to terminals of a 12 volt car battery. WARNING: When deployment is achieved, there will be a loud bang and airbag will inflate. Wait at least 20 minutes before approaching vehicle. Let airbag cool off and dust settle. OUT OF VEHICLE DEPLOYMENT 1. Disconnect battery ground cable. 2. Remove airbag module from steering wheel. 3. Cut wiring harness that goes from clockspring to airbag as close to clockspring as possible. 4. Place other end of harness back into airbag module. 5. Strip one inch of insulation from cut end of harness and connect two 20 ft. wires. 6. Place airbag module face up and move at least 20 ft. away. 7. Touch two ends of 20 ft. long wires to terminals of a 12 volt battery. WARNING: When deployment is achieved, there will be a loud bang and airbag will inflate. Wait at least 20 minutes before approaching, let airbag cool off and dust settle. Airbag Module Storage & Handling WARNING: Before attempting to diagnose, remove or install any airbag system components, unless otherwise noted, you must first disconnect and isolate battery ground cable. Failure to do so could result in accidental deployment and possible personal injury. STORAGE - The airbag module must be stored in its original special container until it is used. - It must be stored in a clean, dry place, away from heat, sparks and sources of electricity. - Always place or store the module on a surface with the trim cover facing up. HANDLING WARNINGS: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3905 - At no time should any source of electricity be permitted near the inflator on the back of the module. - When handling a live module, the trim cover should be pointed away from the body to minimize injury in the event of accidental deployment. - Always place or store the module on a surface with the trim cover facing up. Cleanup Procedure Wear Safety Glasses and Rubber Gloves - Typical WARNING: If you experience skin irritation during cleanup, run cool water over the affected area. also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Following an airbag system deployment, the vehicle interior will contain a powdery residue. This residue is primarily sodium bicarbonate (baking soda), used as an airbag cushion lubricant. However, there will also be traces of sodium hydroxide powder, a chemical by-product of the generant used for airbag deployment. Since this powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. Fig 3 Airbag Exhaust Vent Sealing Begin the cleanup by applying tape over the airbag exhaust vent so no more powder will be released into the vehicle. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on an uncleaned area. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3906 Vacuum Heater and A/C Outlets - Typical Be sure to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioning blower on the lowest speed setting and vacuum any powder expelled from the outlets. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Place the deployed airbag modules in your vehicular scrap pile. Driver Side Airbag Module Replacement UNDEPLOYED At no time should any source of electricity be permitted near the inflator on the back of an airbag module. when carrying a non-deployed airbag module, the trim cover or airbag side of the module should be pointed away from the body to minimize injury in the event of an accidental deployment. If the module is placed on a bench or any other surface, the trim cover or airbag side of the module should be face up to minimize movement in the event of an accidental deployment. In addition, the airbag system should be disarmed whenever any steering wheel, steering column, or instrument panel components require diagnosis or service. Failure to observe this warning could result in accidental airbag deployment and possible personal injury. DEPLOYED Any vehicle which is to be returned to use after an airbag deployment, must have both airbag modules, and the clockspring replaced. These components will be damaged or weakened as a result of an airbag deployment, which may or may not be obvious during a visual inspection, and are not intended for reuse. Other vehicle components should be closely inspected. but are to be replaced only as required by the extent of the visible damage incurred. Wear Safety Glasses and Rubber Gloves - Typical CLEANUP PROCEDURE WARNING: If you experience skin irritation during cleanup, run cool water over the affected area. also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Following an airbag system deployment, the vehicle interior will contain a powdery residue. This residue is primarily sodium bicarbonate (baking soda), used as an airbag cushion lubricant. However, there will also be traces of sodium hydroxide powder, a chemical by-product of the generant used for airbag deployment. Since this powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3907 long-sleeved shirt during cleanup. Fig 3 Airbag Exhaust Vent Sealing Begin the cleanup by applying tape over the airbag exhaust vent so no more powder will be released into the vehicle. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on an uncleaned area. Vacuum Heater and A/C Outlets - Typical Be sure to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioning blower on the lowest speed setting and vacuum any powder expelled from the outlets. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Place the deployed airbag modules in your vehicular scrap pile. Fig 5 Speed Control Switch Remove/Install Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3908 REMOVAL AND INSTALLATION WARNING: This system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the airbag system or related steering wheel and steering column components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag system deployment and possible personal injury. When removing a deployed airbag module, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag module and other interior surfaces. In large doses these deposits may cause irritation to the skin and eyes. 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed, wait two minutes for the system capacitor to discharge before further service. 2. From the underside of the steering wheel remove the speed control switch or trim bar mounting screws. Fig 6 Speed Control Switch Connector Remove/Install 3. Pull the switches or trim bar from the steering wheel. If equipped with speed control, unplug the wiring connector from the switch. Fig 7 Airbag Module Remove/Install 4. Remove the four nuts attaching the airbag module to the steering wheel. 5. Remove the airbag module from the steering wheel. 6. Unplug the electrical connector from the airbag module. 7. When installing, connect the clockspring wiring connector to the module by pressing straight in on the connector. The connector should latch securely beneath the module connector locking clip arms to assure positive connection. 8. Install the four airbag module mounting nuts and tighten to 9 to 11 Nm (80 to 100 in lb). 9. Install the speed control switch or trim bar as equipped. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 3909 10. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Air Bag(s) Arming and Disarming/Service and Repair Service of Deployed Airbag Module Any vehicle which is to be returned to use after an airbag deployment, must have both airbag modules, and the clockspring replaced. These components will be damaged or weakened as a result of an airbag deployment, which may or may not be obvious during a visual inspection, and are not intended for reuse. Other vehicle components should be closely inspected. but are to be replaced only as required by the extent of the visible damage incurred. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Airbag Control Module 4 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 3915 Airbag Control Module 13 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 3918 Air Bag Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 3919 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3920 Air Bag Control Module: Description and Operation AIR BAG CONTROL MODULE (ACM) The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F20. Circuits F14 and F20 are connected to separate bus bars in the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. Circuit F20 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. In the START or RUN positions, the ignition switch connects circuit A21 circuit with circuit A1 from fuse C in the PDC. Circuit A21 circuit supplies battery voltage to the fuse block bus bar that feeds circuit F14. Fuse 14 in the fuse block protects circuit F14. When the ignition switch is in the RUN position, it connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies battery voltage to the fuse block bus bar that feeds circuit F20. Fuse 3 in the fuse block protects circuit F20. The ACM is case grounded and has an external dedicated ground, circuit Z6. Circuit Z6 connects to the right fender side shield. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3921 Air Bag Control Module: Testing and Inspection Circuit F14 is double crimped at fuse 14 in the fuse block to feed the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3922 Air Bag Control Module: Service and Repair WARNING: The ACM contains one of the impact sensors which enable the system to deploy the airbag. To avoid accidental deployment, never connect the ACM electrically to the system unless it is bolted to the vehicle. Before beginning any airbag system removal or installation procedures, disconnect and isolate the battery negative (ground) cable from the vehicle battery. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment, and possible personal injury. 1. Disconnect and isolate the battery negative cable. If the airbag is undeployed, wait two minutes for the system capacitor to discharge before further service. Fig 10 Knee Bolster Remove/Install 2. Remove the screws at the lower edge of the knee blocker/steering column cover. 3. Pull the knee blocker/steering column cover down to disengage the slide tabs from the instrument cluster bezel and remove the knee blocker/steering column cover. Fig 11 Gear Selector Indicator Cable Remove/Install 4. If so equipped, disconnect the automatic transmission gear selector indicator cable from the steering column. 5. Remove the two steering column support nuts. 6. Remove the windshield pillar garnish mouldings and the cowl side trim panels. 7. Loosen the instrument panel pivot bolts in the cowl side panels. 8. Remove the five screws from the instrument panel at the base of the windshield and roll the instrument panel down. - Attach a hook from the windshield fence line to the center of the instrument panel mount to hold the instrument panel in position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3923 Fig 12 Airbag Control Module Replacement 9. Unplug the two electrical connectors from the ACM. 10. Remove the four screws holding the ACM to the mounting bracket. 11. Remove the ACM. 12. To install position the ACM with the arrow pointing iorward. 13. Attach the ACM to the mounting bracket with the four screws. Tighten the mounting screws to 3 - 5 Nm (25 - 45 in lb). 14. Connect the wiring to the ACM, making sure both of the connectors are fully-seated and their locking tabs are engaged. 15. Reverse the remaining removal procedures to complete the installation. - Tighten the steering column support nuts to 12 Nm (105 in lb). 16. Do not connect the battery negative cable at this time. See Airbag System Arming for the proper procedure. See: Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3928 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3929 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3930 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3931 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3932 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3933 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3934 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3935 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3936 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3937 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3938 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3939 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 3940 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 3945 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations Airbag Module, Connector And Clockspring Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations > Page 3948 Clockspring 2 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 3949 Clockspring Assembly / Spiral Cable: Description and Operation DESCRIPTION The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. OPERATION The clockspring is used to maintain a continuous electrical circuit between the wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. See Adjustments for more information. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the airbag has been deployed, the clockspring must be replaced. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 3950 Clockspring Assembly / Spiral Cable: Adjustments Fig. 43 Auto-locking clockspring CENTERING NOTE: If rotating part of clockspring is not properly positioned with steering column and front wheels, clockspring may fail during use. The following procedure must be used if clockspring is not known to be properly positioned. 1. Position front wheels straight ahead. 2. Depress plastic locking pins to disengage locking mechanism. 3. With locking mechanism disengaged, rotate clockspring rotor in clockwise direction to end of travel. Do not apply excessive force. 4. From end of travel, rotate clockspring rotor 2 1/2 turns in counterclockwise direction. The horn wire should be at top and squib wire at bottom. Visually inspect clockspring for bends or kinks; if indicated, replace clockspring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal Clockspring Assembly / Spiral Cable: Service and Repair Removal WARNING: The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting the procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side airbag module. 4. Remove the steering wheel with a steering wheel puller (Special Tool C-3428B). 5. Unplug wiring for the horn switches. 6. Remove the upper and lower steering column shrouds to gain access to the clockspring wire harness connectors. 7. Disconnect the two-way connector between the clockspring and the instrument panel wiring harness at the base of the steering column. 8. To remove, lift the locating fingers of the clockspring assembly from the steering column as necessary. The clockspring cannot be repaired. It must be replaced if faulty, or if the airbag system has been deployed. 9. When installing, snap the clockspring onto the steering column. If the clockspring is not properly positioned, see Clockspring Centering before installing the steering wheel. 10. Connect the clockspring wiring to the instrument panel wiring harness. Be certain that the wiring locator clips are properly seated on the outside of the wiring trough and that the locking tabs are engaged. 11. Reinstall the steering column shrouds. Be certain that the airbag wire is inside the shrouds. 12. The front wheels should still be in the straight-ahead position. Install the steering wheel being certain to fit the flats on the hub of the steering wheel onto the formations on the inside of the clockspring. 13. Pull the horn wiring through the upper, smaller hole in the steering wheel hub. Pull the airbag and speed control wiring through the bottom, larger hole in the steering wheel hub. Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Be certain not to pinch the wiring between the steering wheel and the nut. 14. Connect the horn switch wire, then the airbag wire to the airbag module. To assure complete connection, the latching arms must be visibly on top of the airbag wiring connector housing. 15. Install the airbag module and tighten the nuts to 9 - 11 Nm (80 - 100 in lb). 16. Do not connect the battery negative cable at this time. SEE Airbag System Arming for the proper procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 3953 Clockspring Assembly / Spiral Cable: Service and Repair Centering Fig. 43 Auto-locking clockspring CENTERING NOTE: If rotating part of clockspring is not properly positioned with steering column and front wheels, clockspring may fail during use. The following procedure must be used if clockspring is not known to be properly positioned. 1. Position front wheels straight ahead. 2. Depress plastic locking pins to disengage locking mechanism. 3. With locking mechanism disengaged, rotate clockspring rotor in clockwise direction to end of travel. Do not apply excessive force. 4. From end of travel, rotate clockspring rotor 2 1/2 turns in counterclockwise direction. The horn wire should be at top and squib wire at bottom. Visually inspect clockspring for bends or kinks; if indicated, replace clockspring. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations Diagnostic Connector: Locations Data Link Connector Vehicle will be equipped with one of these three connectors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 3957 Vehicle will be equipped with one of these three connectors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 3958 Diagnostic Connector: Description and Operation CIRCUIT OPERATION The DRB scan tool connects to the data link connector. A twisted pair of wires, circuits D1 and D2, send and transmit data between the Airbag Control Module (ACM) and the DRB scan tool. Circuit A4 from fuse F in the Power Distribution Center (PDC) powers circuit M1 through fuse 2 in the PDC. Circuit M1 supplies voltage to the data link connector. Ground circuit Z12 also connects to the data link connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Impact Sensor Location Impact Sensor Location Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 3963 Impact Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 3964 Impact Sensor: Diagrams Left Impact Sensor Connector Right Impact Sensor Connector Impact Sensor 4 Way Harness Connector -- To Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 3965 Impact Sensor 4 Way Harness Connector -- To Sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 3966 Impact Sensor: Description and Operation DESCRIPTION Two impact sensors and a safing sensor provide verification of the direction and severity of an impact. The safing sensor is located inside the Airbag Control Module (ACM), which is mounted to a bracket on the floor transmission tunnel, under the instrument panel. The two impact sensors are mounted on the inner fender extension panels behind the grille opening reinforcement, on the left and right sides of the vehicle. OPERATION The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The safing sensor is an accelerometer that senses the rate of deceleration. The sensors are calibrated for the specific vehicle, and are sensitive to both the severity and the direction of an impact. The microprocessor in the ACM monitors the sensor signals. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the driver side airbag. REPLACEMENT The impact sensors and safing sensor cannot be repaired or adjusted and, if faulty or damaged, they must be replaced. The impact sensors are available for service replacement. The safing sensor is only serviced as part of the ACM. CIRCUIT OPERATION The airbag system uses two impact sensors. Circuits R47 and R49 connect from the left sensor to the Airbag Control Module (ACM). Circuits R46 and R48 connect the right sensor to the ACM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 3967 Impact Sensor: Service and Repair Fig 8 Battery Holddown Remove/Install LEFT SIDE 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed wait two minutes for the system capacitor to discharge before further service. 2. Remove the battery holddown and move the battery rearward. 3. Unplug the connector from the left impact sensor. Fig 9 Impact Sensor -- Typical 4. Remove the three nuts holding the left sensor to the closure panel support and remove the sensor. 5. To install mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb) . 6. Connect the left sensor wiring to the connector on the body of the sensor. 7. Install the battery holddown strap. Be certain the battery is properly positioned in the battery tray. Tighten the holddown bolts to 2.2 N.m (20 in lb). 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Air Bag(s) Arming and Disarming/Service and Repair RIGHT SIDE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 3968 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed, wait two minutes for the system capacitor to discharge before further service. 2. Pull the air cleaner fresh air inlet tube off of the radiator support. 3. Unplug the connector from the right impact sensor. 4. Remove the three nuts holding the right sensor to the closure panel support and remove the sensor. 5. To install, mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb). 6. Connect the right sensor wiring to the connector on the body of the sensor. 7. Install the air cleaner inlet tube to the radiator support. 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Malfunction Lamp / Indicator: Locations The warning lamp is located in the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 3972 Mechanical Instrument Cluster -- Red Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 3973 Malfunction Lamp / Indicator: Description and Operation OPERATION The airbag indicator lamp lights for 6 to 8 seconds each time the ignition switch is turned ON. The light indicates a system self test is being performed by the air bag control module. If the lamp remains ON after the self-test or comes on while driving, an air bag system malfunction has been detected and the air bag may be inoperative. CIRCUIT OPERATION The airbag warning lamp illuminates when the Airbag Control Module (ACM) provides ground for the lamp on circuit R41. Circuit R41 from the Airbag Control Module (ACM) provides ground for the airbag warning lamp. The airbag warning lamp is part of the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 3978 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 3979 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 3980 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 3981 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 3982 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Airbag Control Module 4 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 3989 Airbag Control Module 13 Way Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 3992 Air Bag Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 3993 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3994 Air Bag Control Module: Description and Operation AIR BAG CONTROL MODULE (ACM) The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F20. Circuits F14 and F20 are connected to separate bus bars in the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. Circuit F20 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. In the START or RUN positions, the ignition switch connects circuit A21 circuit with circuit A1 from fuse C in the PDC. Circuit A21 circuit supplies battery voltage to the fuse block bus bar that feeds circuit F14. Fuse 14 in the fuse block protects circuit F14. When the ignition switch is in the RUN position, it connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies battery voltage to the fuse block bus bar that feeds circuit F20. Fuse 3 in the fuse block protects circuit F20. The ACM is case grounded and has an external dedicated ground, circuit Z6. Circuit Z6 connects to the right fender side shield. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3995 Air Bag Control Module: Testing and Inspection Circuit F14 is double crimped at fuse 14 in the fuse block to feed the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3996 Air Bag Control Module: Service and Repair WARNING: The ACM contains one of the impact sensors which enable the system to deploy the airbag. To avoid accidental deployment, never connect the ACM electrically to the system unless it is bolted to the vehicle. Before beginning any airbag system removal or installation procedures, disconnect and isolate the battery negative (ground) cable from the vehicle battery. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment, and possible personal injury. 1. Disconnect and isolate the battery negative cable. If the airbag is undeployed, wait two minutes for the system capacitor to discharge before further service. Fig 10 Knee Bolster Remove/Install 2. Remove the screws at the lower edge of the knee blocker/steering column cover. 3. Pull the knee blocker/steering column cover down to disengage the slide tabs from the instrument cluster bezel and remove the knee blocker/steering column cover. Fig 11 Gear Selector Indicator Cable Remove/Install 4. If so equipped, disconnect the automatic transmission gear selector indicator cable from the steering column. 5. Remove the two steering column support nuts. 6. Remove the windshield pillar garnish mouldings and the cowl side trim panels. 7. Loosen the instrument panel pivot bolts in the cowl side panels. 8. Remove the five screws from the instrument panel at the base of the windshield and roll the instrument panel down. - Attach a hook from the windshield fence line to the center of the instrument panel mount to hold the instrument panel in position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 3997 Fig 12 Airbag Control Module Replacement 9. Unplug the two electrical connectors from the ACM. 10. Remove the four screws holding the ACM to the mounting bracket. 11. Remove the ACM. 12. To install position the ACM with the arrow pointing iorward. 13. Attach the ACM to the mounting bracket with the four screws. Tighten the mounting screws to 3 - 5 Nm (25 - 45 in lb). 14. Connect the wiring to the ACM, making sure both of the connectors are fully-seated and their locking tabs are engaged. 15. Reverse the remaining removal procedures to complete the installation. - Tighten the steering column support nuts to 12 Nm (105 in lb). 16. Do not connect the battery negative cable at this time. See Airbag System Arming for the proper procedure. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4003 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4009 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4010 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4011 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4012 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4013 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4014 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4015 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4016 detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4017 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4018 POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4019 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4020 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4021 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4022 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4023 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4024 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 4025 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair Seat Belt: Service and Repair CAUTION: Inspect the condition of the shoulder belt and lap belt. Replace any belt that is cut, frayed, torn, or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative. FRONT SEAT BELT RETRACTOR REMOVAL 1. If necessary, move the front seat(s) all the way forward for access. 2. Detach the turning loop cover from the upper anchor bolt. Front Seat Belt Retractor - Bench Seat Bucket Seat Belts Installation - Standard Cab 3. Remove upper anchor bolt. 4. Remove quarter panel trim panel. 5. Detach the turning loop cover from the lower anchor bolt. 6. Remove lower anchor bolt. 7. Remove the retractor anchor bolt. 8. Separate retractor from vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 4029 INSTALLATION 1. Position the retractor in the vehicle. 2. Install the retractor anchor bolt. Tighten the retractor bolt to 40 Nm (350 in. lbs.) torque. 3. Route the lap/seat belt through the quarter trim panel. 4. Install the lower anchor bolt. Tighten the lower anchor bolt to 40 Nm (350 in. lbs.) torque. 5. Install quarter panel trim panel. 6. Install the upper anchor bolt. Tighten the upper anchor bolt to 40 Nm (350 in. lbs.) torque. 7. Install turning loop covers. REAR SEAT BELT RETRACTOR REMOVAL - CLUB CAB 1. Move the front seat(s) all the way forward for access. 2. Remove the rear seat. 3. Detach the turning loop cover from the upper anchor bolt. Rear Seat Belt Retractor - Club Cab 4. Remove upper anchor bolt. 5. Remove quarter panel trim panel. 6. Detach the turning loop cover from the lower anchor bolt. 7. Remove lower anchor bolt. 8. Remove the retractor anchor bolt. 9. Separate retractor from vehicle. INSTALLATION 1. Position the retractor in the vehicle. 2. Install the retractor anchor bolt. Tighten the retractor bolt to 40 Nm (350 in. lbs.) torque. 3. Route the lap/seat belt through the quarter trim panel. 4. Install the lower anchor bolt. Tighten the lower anchor bolt to 40 Nm (350 in. lbs.) torque. 5. Install quarter panel trim panel. 6. Install the upper anchor bolt. Tighten the upper anchor bolt to 40 Nm (350 in. lbs.) torque. 7. Install turning loop covers. FRONT SEAT BELT BUCKLE REMOVAL CAUTION: Inspect the condition of the buckle. Replace any buckle that is or damaged in any way. 1. Move seat to the forward position. 2. Hinge seat back forward. 3. Remove bolt holding seat belt buckle to seat frame (cab back panel for bucket seat equipped vehicles). 4. Separate seat belt buckle from vehicle. INSTALLATION 1. Position the buckle on the floor panel (cab back panel for bucket seat equipped vehicles). 2. Install the anchor bolt. Tighten the anchor bolts to 40 Nm (350 in. lbs.) torque Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 4030 REAR SEAT BELT BUCKLE-CLUB CAB REMOVAL 1. Move the front seat(s) to the full forward position. 2. Remove the rear seat. Rear Seat Belt Retractor - Club Cab 3. Remove seat belt buckle anchor bolt. 4. Separate seat belt buckle from vehicle. INSTALLATION 1. Position the buckle on the floor panel. 2. Install the seat belt buckle anchor bolt. Tighten the anchor bolt to 40 Nm (350 in. lbs.) torque. 3. Install the rear seat. 4. Adjust front seat as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The seat belt indicator warning lamp is activated by the combination buzzer on circuit G13. Circuit G13 supplies power to instrument cluster for the lamp. Circuit Z1 provides ground for the lamp. The Z1 circuit terminates a the instrument panel right lower reinforcement support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4039 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4040 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4041 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4042 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4043 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4044 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4045 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4046 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4047 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4048 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4049 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4050 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 4051 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Impact Sensor Location Impact Sensor Location Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 4056 Impact Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 4057 Impact Sensor: Diagrams Left Impact Sensor Connector Right Impact Sensor Connector Impact Sensor 4 Way Harness Connector -- To Module Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 4058 Impact Sensor 4 Way Harness Connector -- To Sensors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 4059 Impact Sensor: Description and Operation DESCRIPTION Two impact sensors and a safing sensor provide verification of the direction and severity of an impact. The safing sensor is located inside the Airbag Control Module (ACM), which is mounted to a bracket on the floor transmission tunnel, under the instrument panel. The two impact sensors are mounted on the inner fender extension panels behind the grille opening reinforcement, on the left and right sides of the vehicle. OPERATION The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The safing sensor is an accelerometer that senses the rate of deceleration. The sensors are calibrated for the specific vehicle, and are sensitive to both the severity and the direction of an impact. The microprocessor in the ACM monitors the sensor signals. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the driver side airbag. REPLACEMENT The impact sensors and safing sensor cannot be repaired or adjusted and, if faulty or damaged, they must be replaced. The impact sensors are available for service replacement. The safing sensor is only serviced as part of the ACM. CIRCUIT OPERATION The airbag system uses two impact sensors. Circuits R47 and R49 connect from the left sensor to the Airbag Control Module (ACM). Circuits R46 and R48 connect the right sensor to the ACM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 4060 Impact Sensor: Service and Repair Fig 8 Battery Holddown Remove/Install LEFT SIDE 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed wait two minutes for the system capacitor to discharge before further service. 2. Remove the battery holddown and move the battery rearward. 3. Unplug the connector from the left impact sensor. Fig 9 Impact Sensor -- Typical 4. Remove the three nuts holding the left sensor to the closure panel support and remove the sensor. 5. To install mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb) . 6. Connect the left sensor wiring to the connector on the body of the sensor. 7. Install the battery holddown strap. Be certain the battery is properly positioned in the battery tray. Tighten the holddown bolts to 2.2 N.m (20 in lb). 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair RIGHT SIDE Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 4061 1. Disconnect and isolate the battery negative cable. If the airbag module is undeployed, wait two minutes for the system capacitor to discharge before further service. 2. Pull the air cleaner fresh air inlet tube off of the radiator support. 3. Unplug the connector from the right impact sensor. 4. Remove the three nuts holding the right sensor to the closure panel support and remove the sensor. 5. To install, mount the sensor (arrow pointed forward) using the three nuts provided with the new sensor. Tighten the nuts to 3 - 4 Nm (24 - 36 in lb). 6. Connect the right sensor wiring to the connector on the body of the sensor. 7. Install the air cleaner inlet tube to the radiator support. 8. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4067 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4068 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4069 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4074 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4075 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 4076 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation Amplifier: Description and Operation CIRCUIT OPERATION The radio choke relay supplies voltage to the amplifier circuits in the speakers. The radio supplies power to the coil side of the relay on circuit X60. Circuit Z1 provides ground for the coil side of the relay Circuit X1 from fuse 6 in the fuse block supplies power to the contact side of the relay Circuit A3 from fuse G in the Power Distribution Center (PDC) connects to the fuse block bus bar that feeds circuit X1 through fuse 6. Circuits A3 and X1 are HOT at all times. When the radio supplies power for the coil side of the relay on circuit X60, the contact close and connect circuits X1 and X13. Circuit X13 supplies voltage to the amplifier circuits in the speakers. Circuit X15 provides ground for the amplifier circuit of the speakers. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Radio/Stereo: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Radio/Stereo: Electrical Diagrams Standard Radio Audio System Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Audio System NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Premium Radio Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Audio System Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 Audio System Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Audio System NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Audio System Radio/Stereo: Description and Operation Audio System Two radio systems are available in this vehicle; the radio with standard speaker system and a radio with premium speaker system. The premium speaker system uses a power amplifier and radio choke relay not used on the standard speaker system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Audio System > Page 4112 Radio/Stereo: Description and Operation Radio Operation CIRCUIT OPERATION In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) with circuit A31. Circuit A31 powers a bus bar in the fuse block that feeds circuit X12 through fuse 12. Circuit X12 supplies battery voltage to the radio. The radio is case grounded. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Audio System > Page 4113 Radio/Stereo: Description and Operation Radio Memory CIRCUIT OPERATION Circuit M1 from the Ignition Off Draw (IOD) fuse (fuse F2) in the Power Distribution Center (PDC) supplies power for the radio memory. The IOD fuse is removed during vehicle shipping to prevent excessive battery draw. Circuit A4 from fuse F in the PDC supplies voltage to the IOD fuse. Circuit A4 and M1 are HOT at all times. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Audio System > Page 4114 Radio/Stereo: Description and Operation Radio Illumination CIRCUIT OPERATION When the parking lamps or headlamps are on, circuits E2 and L7 from the headlamp switch power the radio illumination lamps. Fuse 13 in the fuse block powers circuit E2 which feeds the radio illumination lamp. Circuit E1 from the headlamp switch supplies power to fuse 13. Circuit L7 supplies voltage for the radio lamps. The radio case ground completes the ground path for the illumination and park lamp circuits. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Page 4115 Radio/Stereo: Testing and Inspection - When the headlamp switch is in the park lamps or headlamp ON position, it connects circuit F33 from fuse 8 in the fuse block with circuits E1 and L7. Circuit E1 is powered by a variable resistor in the headlamp switch used to adjust illumination lamp brightness. - Circuit A3 from fuse G in the PDC feeds the fuse block bus bar that powers circuit F33 through fuse 8. Circuits A3 and F33 are HOT at all times. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Page 4116 Radio/Stereo: Service and Repair Steering Column Cover 1. Disconnect battery ground cable, then remove steering column cover. Fig. 16 Instrumental Cluster & Bezel Removal 2. Remove instrument cluster bezel. 3. Remove two screws attaching radio to instrument panel, then pull radio through front face of panel and disconnect radio electrical connector, antenna lead and ground strap. 4. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard Radio Speaker: Description and Operation Standard Radio CIRCUIT OPERATION Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard Radio > Page 4121 Speaker: Description and Operation Premium Radio CIRCUIT OPERATION When the radio choke relay energizes, circuit X13 supplies voltage to the amplifier circuits in each speaker. Circuit X15 supplies ground for the amplifier circuit. Circuit X15 grounds to the rear of the radio. Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Trailer Connector: Electrical Diagrams Trailer Tow NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 4144 Trailer Connector: Description and Operation CIRCUIT OPERATION The vehicle is equipped with jumper harness for the aftermarket trailer brake controllers. At the time of delivery, the harness is stored under the passengers front seat. The jumper harness connects to an instrument panel harness connector near the steering column. The jumper harness contains circuits L50 from the stop lamp switch, ground circuit Z1, circuit B40 for trailer brakes, and circuit A6 for power supply. The trailer tow harness contains a relay that operates the trailer tail lights. When the headlamps or parking lamps ON, circuit L7 from the headlamp switch powers the coil side of the relay Circuit Z1 provides ground for the relay When the relay energizes, it powers circuit L76. Circuit L76 supplies power to the trailer tow connector for the trailer tail lamps and side marker lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Trailer Connector: Electrical Diagrams Trailer Tow NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 4166 Trailer Connector: Description and Operation CIRCUIT OPERATION The vehicle is equipped with jumper harness for the aftermarket trailer brake controllers. At the time of delivery, the harness is stored under the passengers front seat. The jumper harness connects to an instrument panel harness connector near the steering column. The jumper harness contains circuits L50 from the stop lamp switch, ground circuit Z1, circuit B40 for trailer brakes, and circuit A6 for power supply. The trailer tow harness contains a relay that operates the trailer tail lights. When the headlamps or parking lamps ON, circuit L7 from the headlamp switch powers the coil side of the relay Circuit Z1 provides ground for the relay When the relay energizes, it powers circuit L76. Circuit L76 supplies power to the trailer tow connector for the trailer tail lamps and side marker lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle Front Door Handle: Service and Repair Interior Door Handle INSIDE DOOR HANDLE REMOVAL 1. Raise the window glass to the completely closed position. 2. Remove the door trim panel, the waterdam and the noise insulator from the door inner panel. 3. Remove the handle-to-latch rod from the handle via the access hole. 4. Remove the retaining blind rivet with a drill and remove the inside handle from the door panel. INSTALLATION 1. Insert the inside handle through access hole and into door. 2. Connect the handle-to-latch rod to the handle via the access hole. 3. Attach the inside handle to the door panel with a 1/4-20 x 1/2" bolt and nut. Tighten the nut to 10 Nm (90 in. lbs.) torque. 4. If necessary, adjust to eliminate excess handle travel. 5. Install the door noise-insulator, the waterdam, and the trim panel (or, if applicable, the access panel). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair > Interior Door Handle > Page 4175 Front Door Handle: Service and Repair Exterior Door Handle Door Assembly OUTSIDE DOOR HANDLE REMOVAL 1. Remove the door trim panel, the waterdam and the noise insulator from the door inner panel. 2. Remove the door handle attaching bracket nuts. 3. Disconnect the handle-to-latch rod from the latch. 4. Disconnect the lock cylinder-to-latch rod from the latch. 5. Remove the handle and gasket from the door outer panel. INSTALLATION 1. Apply silicone spray lubricant to the handle's internal moving parts. 2. Position the gasket and handle on the door outer panel. 3. Position the handle attaching bracket at the inside of the handle. 4. Install and tighten the handle attaching bracket nuts securely. 5. Connect the handle-to-latch rod to the latch. 6. Connect the lock cylinder-to-latch rod to the latch. 7. Test and ensure that the handle operates correctly. 8. Install the door-noise insulator, waterdam, trim panel, and access panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair DOOR LATCH REMOVAL 1. Raise the window glass to the completely closed position. 2. Remove the door trim panel, the waterdam and the noise insulator from the door inner panel. 3. Disconnect the following: ^ Outside handle-to-latch rod from the latch ^ Key lock cylinder-to-latch rod from the latch Door Latch And Rods ^ Inside handle-to-latch rod from the latch ^ Lock knob-to-latch rod from the latch, if equipped ^ Lock motor-to-latch rod from the latch Door Latch Removal/Installation 4. Remove the door latch retaining screws from the door inner panel face. 5. Remove the door latch from the door via the access hole in the panel. INSTALLATION 1. Install the latch striker, if removed. 2. Insert the door latch through the access hole in the panel, position it at the door face panel, and connect the rods to it. 3. Install the latch retaining screws in the door panel face. Tighten the screws to 9 Nm (7 ft-lbs) torque. 4. Test and ensure that the latch operates correctly. 5. Install the door-noise insulator, the waterdam, and the trim panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair REMOVAL Power Switch Housing 1. Remove the retaining screw and the power switch housing (if equipped). Door Trim Panel 2. Remove the window regulator handle (if equipped). 3. Remove the door inside latch release handle bezel. 4. Remove the door pull strap (if equipped). 5. Remove retaining screws and the armrest (if equipped). 6. Remove the exterior mirror retaining screw and bezel (if equipped). 7. Using a trim stick or other suitable flat tool, gently pry trim panel away from door and remove the trim panel from the vehicle. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 4182 Door Waterdam 8. Carefully separate the waterdam from the door inner panel at the areas with adhesive. Remove the waterdam from the vehicle. Door Noise Insulator 9. Remove the retainers holding the noise insulator to the door inner panel. Remove the noise insulator from the vehicle. INSTALLATION 1. Position the noise insulator on the inner door panel and install the retainers. 2. Apply a suitable adhesive/sealant to the waterdam edges, and install it onto the inner door panel. 3. Position the trim (or access panel) on the door inner panel and press the fasteners until they snap into the door inner panel. 4. Install the armrest, window regulator handle, pull strap, and power switch (if equipped). Torque the armrest retaining screws to 20 lb-in (3 Nm). Torque the power switch retaining housing screw to 17 lb-in (2 Nm). 5. Install the exterior mirror bezel and retaining screw (if applicable). 6. Install the door inside latch release handle bezel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair DOOR GLASS REMOVAL 1. Remove the door trim panel (or, if applicable, the access panel), the waterdam and the noise insulator. 2. Open the window glass (move the glass down into the door). Door Beltline Moulding Weatherstrip 3. Remove the retaining screws and the beltline weatherstrip moulding from the door. CAUTION: Damage to the window glass rear track channel is possible it the glass is removed without using Tool C-4867 (or an equivalent tool). Door Window Glass Removal/Installation 4. Use Tool C-4867 to disengage the window glass edge sliders from the glass rear track. 5. Rotate the window glass on the regulator roller, slide it rearward and upward at a 45° angle, and remove it from the door. INSTALLATION 1. Install replacement edge sliders on the window glass rear edge. 2. Insert the window glass into the door. 3. Slide it forward and downward at a 45° angle. 4. Engage the window glass edge sliders with the glass rear track. 5. Engage the lift channel with the regulator roller. 6. Position the beltline weatherstrip moulding on the door panel and install the retaining screws. Tighten the screws securely 7. Install the noise insulator, the waterdam and the door trim panel (or, if applicable, the access panel). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Adjustments Hood: Adjustments HOOD FORE/AFT AND LATCH/STRIKER The hood hinge screw holes are oversize and elongated to ease hood up/down and fore/aft position adjustment. Loosen the hinge-to-fender panel screws for up/down adjustment (in relation to the fenders). Loosen the hinge arm-to-hood bolts for fore/aft adjustment (in relation to the cowl). The following sequence of hood fore/aft position and latch lock/striker adjustments must be followed as listed to avoid improper adjustment. An improperly adjusted latch lock or striker can cause the front of the hood to be released and be retained only by the safety latch. 1. Loosen the hinge arm-to-hood bolts at each side of the vehicle. 2. Loosen the bolts attaching the hood latch to the closure panel. 3. Remove the support and close the hood. Adjust the fore/aft position until approximately 5 mm (3/16 in.) clearance exists between the rear of hood panel and the cowl. 4. Raise and support the hood at a 30° angle (approximately). Tighten the hinge arm-to-hood bolts to 23 Nm (200 in. lbs.) torque. 5. Tighten the latch bolts to 10 Nm (95 in. lbs.) torque. 6. Remove the support, lower the hood and visually inspect for correct front fender bumper-to-hood contact. 7. Open and support the hood. Apply a thick layer of modeling clay to the top side of the primary latch striker arm. 8. Remove the support and close the hood to obtain a latch-position impression in the clay 9. Open and support the hood. Observe the latch impression in the clay A properly adjusted latch will produce a centered-position impression in the clay/striker. If the impression is not correct, re-adjust the hood latch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair CARPET AND/OR FLOOR MAT REMOVAL 1. Remove: ^ The seat(s) ^ The scuff plates ^ The transmission and transfer case floor shift levers, bezels and boots ^ The floor console ^ All other interfering attached components. (If needed refer to applicable installation procedures). 2. Remove the carpet/mat from the floor panel. INSTALLATION 1. Position the carpet/mat on the floor panel. 2. Install seat(s) and all components that were removed to ease carpet/mat removal. If needed, refer to applicable installation procedures. 3. Install the trim panels, mouldings and scuff plates. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 Console: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Console: Electrical Diagrams Overhead Console (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 Overhead Console (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 4215 Console: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, circuit F20 from fuse 3 in the fuse block supplies power to the overhead console. Circuit F20 is double crimped at the overhead console and connects to the day/night mirror. When the headlamps or parking lamps are ON, circuits L7 and E2 provide voltage to the overhead console for illumination. Circuit E2 from flise 13 in the fuse block powers the illumination lamps in the overhead console. Circuit E1 from the headlamp switch feeds fuse 13 and circuit E2. Circuit Z2 provides ground for the compass. Circuit Z1 provides ground for the reading lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 4216 Console: Service and Repair Center Console Mounting FLOOR CONSOLE REMOVAL 1. Remove the front bin and remove the console front attaching screws from the floor panel crossmember. 2. Open the console lid and remove the console rear attaching screws from the floor bracket. 3. Remove the console from the floor bracket and the floor panel. INSTALLATION 1. Position the console on the floor panel and bracket. 2. Install the attaching screws in the panel and bracket. Tighten the screws to 4 Nm (35 in. lbs.) torque. 3. Install the front bin and close the lid. Rear Storage Box - Club Cab REAR STORAGE BOX-CLUB CAB REMOVAL 1. Open the storage box covers and remove the attaching screws from the floor panel and crossmember. 2. Remove the storage box from the floor panel. INSTALLATION 1. Position the storage box on the floor panel. 2. Install the attaching screws in the floor panel and crossmember. Tighten the screws to 4 Nm (35 in. lbs.) torque. 3. Close the covers. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4222 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner And Sun Visor The Dakota standard equipment cab headliner is a molded hardboard. A cloth-cover molded cab headliner is used with SLT model. HEADLINER REMOVAL CAUTION: A cab headliner is a one-piece, molded hardboard. It has limited flexibility and must not be bent during removal/installation. 1. Remove the sunvisors and retaining clips. 2. Remove the windshield trim mouldings, B-pillar panels or quarter panels (club cab) and rear window upper trim moulding. If necessary, refer to the removal procedure. 3. As applicable, remove the dome/cargo lamp, the map/reading lamp and/or overhead console. If necessary, refer to the removal procedures. 4. Remove the retaining screws and the assist handle. 5. Remove the retaining screws and the coat hook. 6. Remove all other headliner interfering components. 7. Remove the headliner retaining screws. 8. Carefully remove the headliner from the cab. INSTALLATION 1. Carefully position the headliner in the cab adjacent to the roof panel. 2. Install the headliner retaining screws. Tighten the screws to 4 Nm (35 in. lbs.) torque. 3. Position the assist handle on the headliner and install the retaining screws. Tighten the screws to 4 Nm (35 in. lbs.) torque. 4. Position the coat hook on the headliner and install the retaining screws. Tighten the screws to 4 Nm (35 in. lbs.) torque. 5. Install the trim mouldings/panels, lamps and all other components that were removed for headliner access. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair SUNVISORS REMOVAL 1. Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. 2. Detach the sunvisor from the retaining clip. 3. Remove the sunvisor from the headliner and roof panel. 4. Remove the attaching screw and the retaining clip from the headliner and the roof panel. INSTALLATION 1. Install the sunvisor retaining clip with the attaching screw. 2. Position the sunvisor in the retaining clip and align the arm support bracket holes with the headliner holes. 3. Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. Tighten the screws to 4 Nm (35 in. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair Interior Trim Panels - Conventional Cab Interior Garnish Mouldings - Extended Cab Dakota cab interior trim panels are comprised of the following: ^ Windshield side moldings ^ Cowl side covers ^ Sill plate covers ^ Seat belt retractor covers ^ B-pillar or rear quarter covers ^ Rear window lower molding All the interior trim panels are attached with screws and clips. CAUTION: Do not attempt to remove interior trim panels/moldings without first removing the necessary adjacent panels. To avoid damaging the panels, ensure that all screws and clips are removed before attempting to remove an interior trim panel/molding. Trim panels are somewhat flexible, but can be damaged if handled improperly. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 4232 Grab Handle Mounting OVERHEAD ASSIST HANDLE REMOVAL 1. Using a small flat-blade, carefully remove the access plug from the overhead assist handle. 2. Remove screws holding overhead assist handle to roof rail. 3. Separate overhead assist handle from vehicle. INSTALLATION 1. Position handle at roof rail. 2. Install screws. 3. Position access plug in handle and push into place. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER REMOVAL 1. Raise the window glass to the completely closed position. 2. Remove the door trim panel, the access panel, the waterdam and the noise insulator. 3. Remove nut and wire retainer attaching lock cylinder to outside handle. Key Lock Cylinder And Outside Handle 4. Disconnect the lock cylinder-to-latch rod at the door latch. 5. Remove the key lock cylinder clip retainer and remove the lock cylinder from the door. 6. If being replaced, remove the lock cylinder latch rod from the original lock cylinder and attach it to the replacement lock cylinder. INSTALLATION 1. Install the lock cylinder in the door hole. Retain the lock cylinder with the clip retainer. 2. Connect the lock cylinder-to-latch rod to the door latch. 3. Install retaining wire and nut. 4. Test the door lock cylinder-to-latch rod operation. 5. Install the door trim panel, the waterdam, and, the noise insulator. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the left door lock switch is moved to the LOCK position, voltage is supplied on circuit P35 to the LOCK bus bar inside the right door switch . Battery voltage is passed through the right door switch to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the left door lock switch is moved to the UNLOCK position, voltage is supplied on circuit P36 to the UNLOCK bus bar inside the right door switch. Battery voltage is passed through the right door switch to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 4243 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the right door switch is moved to the LOCK position, voltage is supplied to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the right door switch is moved to the UNLOCK position, voltage is supplied to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on Z1 circuit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 4244 Power Door Lock Switch: Testing and Inspection - Check fuse G in the PDC. - Check fuse 5 in the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions Mirrors: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Mirrors: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Mirrors: Electrical Diagrams Power Mirrors NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors Mirrors: Description and Operation Power Mirrors CIRCUIT OPERATION A single switch operates both the left and right power mirrors. Each mirror has two motors; a LEFT/RIGHT motor and a UP/DOWN motor. The motors switch polarity to allow mirror adjustment. Circuit A4 from fuse F in the Power Distribution Center (PDC) supplies battery voltage to the Ignition Off-Draw (IOD) fuse in cavity 2 in the PDC. The IOD fuse powers the power mirror switch on circuit M1. Circuit Z1 connects to the power mirror switch and supplies ground for the power mirror system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors > Page 4268 Mirrors: Description and Operation Day/Night Mirror CIRCUIT OPERATION The day/night mirror receives power from circuit F20 when the ignition switch is in the RUN position. Circuit Z1 provides ground for the day/night mirror. When the back-up lamps switch closes, circuit L1 provides a signal to the day/night mirror. The day night mirror turns OFF when the vehicle is in reverse. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors > Page 4269 Mirrors: Description and Operation Left Power Mirror Operation CIRCUIT OPERATION In the LEFT position, the power mirror switch supplies power to the left mirror LEFT/RIGHT motor on circuit P73 when a RIGHTWARD adjustment is made. Circuit P71 provides the ground path the for RIGHTWARD adjustments. When the operator makes LEFTWARD adjustment, polarity reverses. For LEFTWARD adjustments, the switch supplies battery voltage the left mirror LEFT/RIGHT motor on circuit P71. Circuit P73 supplies ground for LEFTWARD adjustments. During UPWARD adjustments, the switch supplies voltage to the left mirror UP/DOWN motor on circuit P75. Circuit P73 supplies ground during UPWARD adjustments. For DOWNWARD adjustments, the polarity is reversed, the switch powers the left mirror UP/DOWN motor on circuit P73. Circuit P75 supplies the ground path. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Power Mirrors > Page 4270 Mirrors: Description and Operation Right Power Mirror Operation CIRCUIT OPERATION In the RIGHT position, the power mirror switch supplies power to the right mirror LEFT/RIGHT motor on circuit P7O when a RIGHTWARD adjustment is made. Circuit P74 provides the ground path the for RIGHTWARD adjustments. When the operator makes a LEFTWARD adjustment, polarity reverses. For LEFTWARD adjustments, the switch supplies battery voltage the right mirror LEFT/RIGHT motor on circuit P74. Circuit P70 supplies ground for LEFTWARD adjustments. During UPWARD adjustments, the switch supplies voltage to the right mirror UP/DOWN motor on circuit P72. Circuit P70 supplies ground during UPWARD adjustments. For DOWNWARD adjustments, the polarity is reversed, the switch powers the right mirror UP/DOWN motor on circuit P70. Circuit P72 supplies the ground path. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Description and Operation > Page 4271 Mirrors: Testing and Inspection - Check fuse F in the Power Distribution Center (PDC). - Check the IOD fuse in cavity 2 in the PDC. - Circuit M1 supplies voltage to the radio memory, lamp, underhood lamp, time delay relay, dome lamp, overhead console lamps and glove box lamp. Check for proper operation of these items. - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror Mirrors: Service and Repair Inside Rear View Mirror Rear View Mirror 1. Using a wax pencil, locate and mark the mounting position of the button on the outside of the windshield. 2. If the vinyl pad had remained on the windshield glass, apply "low heat" to it with an electric heat gun until the vinyl softens; then peel the vinyl pad from the glass. 3. Thoroughly clean the inner surface of the windshield glass in the mounting area of the mirror button using a mild abrasive cleaning powder such as Ajax, Comet, or equivalent, on a clean cloth saturated with alcohol. Then, apply alcohol to a paper towel and wipe off any traces of remaining cleaner. 4. Thoroughly sand the windshield mounting surface (the side with least surface area) of the mirror button with a clean piece of fine grit sandpaper and wipe the surface clean with a clean paper towel saturated with alcohol. 5. Using kit 4054099 or equivalent, crush the vial in the plastic housing of the accelerator. This saturates the felt applicator. Remove paper sleeve. Apply a generous amount of accelerator on the mounting surface of the mirror button. 6. Allow the accelerator to dry for 5 minutes. Do not touch the mounting surface of the button or glass. 7. Apply a thin film of Accelerator to the inner surface of the windshield in the button mounting area. Allow one minute to dry. Do not touch the surface. 8. Apply one drop of Adhesive to the center of the windshield mounting surface of the mirror button and, using the bottom of the Adhesive tube, quickly distribute the adhesive evenly over the entire bonding surface of the button. 9. Position the bottom straight edge of the mirror button on the horizontal line and center it on the vertical line and press it firmly to the glass and apply pressure for about one minute. Proper location is essential as cement sets up very fast. 10. Allow five minutes for the adhesive to set; then, remove any excess adhesive residue from the windshield in the attachment area using an alcohol-dampened cloth. 11. Slide the mirror downward onto the button and tighten the screw. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror > Page 4274 Mirrors: Service and Repair Outside Rear View Mirror REMOTE/MANUAL SIDE VIEW MIRROR REMOVAL Remote/Manual Mirror 1. Loosen the mirror toggle control setscrew at the bezel. 2. Remove the cover plug and the mirror bezel retaining screw. Remove the mirror bezel from the door trim panel and the toggle control. 3. Remove the seal from the door aperture for access to the mirror retaining nuts. 4. Remove the mirror retaining nuts. 5. Remove the mirror from the door outside panel. INSTALLATION 1. If necessary, clean the door panel to mirror base contact surface. 2. Position the mirror on the door outside panel with the studs inserted in the holes. 3. Install the mirror retaining nuts. Tighten the nuts to 7 Nm (65 in. lbs.) torque. 4. Install the mirror seal in the door aperture. 5. Position the mirror bezel over the toggle control and tighten the setscrew to 1 Nm (9 in. lbs.) torque. 6. Install the mirror bezel retaining screw. Tighten the screw to 2 Nm (17 in. lbs.) torque. 7. Install the mirror bezel retaining screw cover plug. NON-REMOTE/MANUAL AND WIDE-VIEW MIRRORS REMOVAL 1. Remove the cover plug and the mirror bezel retaining screw. Remove the mirror bezel from the door trim panel. Non-Remote/Manual And Wide-view Mirrors 2. Remove the seal for access to the mirror retaining nuts. 3. Remove the mirror retaining nuts. 4. Remove the mirror from the door outside panel. INSTALLATION 1. If necessary, clean the door panel to mirror base contact surface. 2. Position the mirror on the door outside panel with the studs inserted in the holes. 3. Install the mirror retaining nuts. Tighten the nuts to 7 Nm (65 in. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror > Page 4275 4. Install the mirror seal in the door aperture. 5. Position the mirror bezel over the door aperture. 6. Install the bezel retaining screw. Tighten the screw to 2 Nm (17 in. lbs.) torque. 7. Install the mirror bezel retaining screw cover plug. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 4281 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 4282 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 4283 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 4284 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 4285 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the left door lock switch is moved to the LOCK position, voltage is supplied on circuit P35 to the LOCK bus bar inside the right door switch . Battery voltage is passed through the right door switch to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the left door lock switch is moved to the UNLOCK position, voltage is supplied on circuit P36 to the UNLOCK bus bar inside the right door switch. Battery voltage is passed through the right door switch to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 4291 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the right door switch is moved to the LOCK position, voltage is supplied to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. Unlock CIRCUIT OPERATION When the right door switch is moved to the UNLOCK position, voltage is supplied to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on Z1 circuit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 4292 Power Door Lock Switch: Testing and Inspection - Check fuse G in the PDC. - Check fuse 5 in the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 233496 > May > 96 > Front Doors - Wind Noise Weatherstrip: Customer Interest Front Doors - Wind Noise NO: 23-34-96 GROUP: Body DATE: May 31, 1996 SUBJECT: Windnoise Around Front Doors MODELS: 1996 (AN) Dakota Note: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO FEBRUARY 21, 1996 (MDH 02-21-XX). SYMPTOM/CONDITION: Vehicles may exhibit a windnoise coming from the top of the door near the A-pillar on the right and/or left door. The windnoise can be heard as a loud buzzing/squealing/vibrating noise noticeable when the vehicle is in motion and most prominent at higher speeds (around 65 mph). High speed air flow over the body/door hem flange edge gap causes the bulb on the body-to-door-seal to vibrate. DIAGNOSIS: Drive the vehicle at highway speeds, preferably with cross wind conditions which may be required to produce this noise. Drive the vehicle in a variety of directions relative to wind direction. The noise is very distinctive and should not be confused with other windnoise such as whistling/rushing type noise. The noise is usually heard at the top of the door near the A-pillar, but it is possible that the noise can come from other areas around the top of the door opening. If the above condition is noticed while driving the vehicle, perform the Repair Procedure. PARTS REQUIRED: 1 (per door) 55256990 Body-to-door-seal REPAIR PROCEDURE: This bulletin involves replacing the existing body-to-door-seal with a revised seal. 1. Pull the body-to-door seal outward to separate the seal from the retainer flange. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 233496 > May > 96 > Front Doors - Wind Noise > Page 4301 2. Push the new seal (P/N 55256990) onto the retainer flange. Position the rear end of the seal flush to the rear end of the door/pillar drip rail seal flange (figure 1). CAUTION: DO NOT USE A HAMMER TO INSTALL THE BODY-TO-DOOR-SEAL. 3. Move forward to the A-pillar while seating the body-to-door-seal on the flange. The top of the seal must fit tight against the roof to provide a proper water-tight seal and to have a good appearance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Seal, Body to Door - Replace (One or Both) 23-51-08-91 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 233496 > May > 96 > Front Doors - Wind Noise Weatherstrip: All Technical Service Bulletins Front Doors - Wind Noise NO: 23-34-96 GROUP: Body DATE: May 31, 1996 SUBJECT: Windnoise Around Front Doors MODELS: 1996 (AN) Dakota Note: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO FEBRUARY 21, 1996 (MDH 02-21-XX). SYMPTOM/CONDITION: Vehicles may exhibit a windnoise coming from the top of the door near the A-pillar on the right and/or left door. The windnoise can be heard as a loud buzzing/squealing/vibrating noise noticeable when the vehicle is in motion and most prominent at higher speeds (around 65 mph). High speed air flow over the body/door hem flange edge gap causes the bulb on the body-to-door-seal to vibrate. DIAGNOSIS: Drive the vehicle at highway speeds, preferably with cross wind conditions which may be required to produce this noise. Drive the vehicle in a variety of directions relative to wind direction. The noise is very distinctive and should not be confused with other windnoise such as whistling/rushing type noise. The noise is usually heard at the top of the door near the A-pillar, but it is possible that the noise can come from other areas around the top of the door opening. If the above condition is noticed while driving the vehicle, perform the Repair Procedure. PARTS REQUIRED: 1 (per door) 55256990 Body-to-door-seal REPAIR PROCEDURE: This bulletin involves replacing the existing body-to-door-seal with a revised seal. 1. Pull the body-to-door seal outward to separate the seal from the retainer flange. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 233496 > May > 96 > Front Doors - Wind Noise > Page 4307 2. Push the new seal (P/N 55256990) onto the retainer flange. Position the rear end of the seal flush to the rear end of the door/pillar drip rail seal flange (figure 1). CAUTION: DO NOT USE A HAMMER TO INSTALL THE BODY-TO-DOOR-SEAL. 3. Move forward to the A-pillar while seating the body-to-door-seal on the flange. The top of the seal must fit tight against the roof to provide a proper water-tight seal and to have a good appearance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Seal, Body to Door - Replace (One or Both) 23-51-08-91 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch from mounting bracket, then disconnect switch from wiring harness. 2. Using a suitable ohmmeter, ensure switch continuity is as follows: a. With switch plunger released, continuity should exist between pins 5 and 6. b. With switch plunger depressed, continuity should exist between pins 1 and 2 and between pins 3 and 4. 3. If switch continuity is as specified, switch is satisfactory; if not, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection Speed Control Servo: Testing and Inspection 1. Start engine, then disconnect 4-way electrical connector at servo. 2. Place speed control switch in On position, then inspect for battery voltage at pin No. 3. Battery voltage should be present when brake is released and not present when brake pedal is depressed. 3. If voltage is not as specified, then inspect stop lamp switch adjustment and inspect for continuity between stop lamp switch and servo. 4. Connect a jumper wire between pin No. 3 of connector and pin No. 3 of servo. 5. Inspect for battery voltage at pins 1, 2 and 4 of servo. Battery voltage should be present. 6. If voltage is not as specified, then replace servo. 7. Place ignition switch In Off position, then inspect for continuity between servo harness connector pin No. 4 and ground. Continuity should exist. 8. If continuity is not as specified, then repair open to ground as required. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair 1. Remove air cleaner. 2. While holding throttle open, remove cable slug from throttle lever cam. 3. Remove cable from bracket at throttle body. 4. Disconnect cable from servo, then remove cable assembly. 5. Reverse procedure to install. Torque nut washers to 50 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4321 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4322 Speed Control Switch: Testing and Inspection 1. Disconnect battery ground cable. 2. Remove speed control switch. Speed Control Switch Continuity 3. Inspect switch continuity as shown. 4. If continuity is not as specified, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4323 Speed Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch from mounting bracket, then disconnect switch from wiring harness. 2. Using a suitable ohmmeter, ensure switch continuity is as follows: a. With switch plunger released, continuity should exist between pins 5 and 6. b. With switch plunger depressed, continuity should exist between pins 1 and 2 and between pins 3 and 4. 3. If switch continuity is as specified, switch is satisfactory; if not, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4331 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4332 Speed Control Switch: Testing and Inspection 1. Disconnect battery ground cable. 2. Remove speed control switch. Speed Control Switch Continuity 3. Inspect switch continuity as shown. 4. If continuity is not as specified, replace switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Locations > Page 4333 Speed Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber lamp monitors anti-lock brake system condition. The lamp will be ON during engine starting, but should go off when the self-diagnostic system determines proper system operation. If the lamp remains ON, a malfunction in the anti-lock brake system is indicated. After diagnosis and repair of the system, the lamp may be turned OFF by disconnecting and reconnecting the anti-lock brake system control module electrical connector or the battery ground cable. The anti-lock brake system control module is located in the passenger compartment and can be accessed after removing the righthand cowl cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation CIRCUIT OPERATION The buzzer module sounds an audible warning tone. The tone sounds for seat belt warning and when the ignition key is in the ignition switch while the drivers door is open. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled. Fuses 7 and 16 in the fuse block protect the buzzer module. Fuse 7 powers circuit F32 which connects to the buzzer module. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies power to the fuse block for fuse 7 and circuit F32. Circuit G5 from fuse 16 in the fuse block also provides voltage to the buzzer module when the ignition switch is in the START or RUN positions. The ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 connects to the fuse block. When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26 connects to the buzzer module and the key-in switch. Circuit G16 from the drivers side door jamb switch also connects to the key-in switch. Circuit G13 from the buzzer powers the seat belt warning lamp in the instrument cluster. Circuit Z1 at the instrument cluster provides ground for the lamp. Circuit G1O from the buzzer connects to the seat belt switch. When the seat belt switch closes a path to ground is completed on circuit Z1. Circuit Z1 also grounds the combination buzzer module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Description and Operation > Page 4341 Audible Warning Device Control Module: Testing and Inspection - Circuit F32 also powers the stop lamp switch. - Circuit G5 is double crimped at the buzzer module. The G5 branch from the buzzer module splices to power the four-wheel drive lamp and the overdrive lamp, and transmission temperature warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Four Wheel Antilock Brakes Brake Warning Indicator: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The Controller, Antilock Brakes (CAB) provides ground for the ABS warning lamp in the instrument cluster through the normally closed contacts in the ABS warning lamp relay. when the ignition switch is in the START position, the lamp illuminates as a bulb test for approx. 3 to 5 Seconds while the CAB performs a system self-test. While closed, the relay contacts complete the ground path for the ABS warning lamp by connecting circuit G19 from the lamp to ground on circuit Z1. Power for the lamp is supplied by circuit F14 from fuse 14 in the fuse block. If the system successfully completes the self-test, the CAB energizes the ABS warning lamp relay by grounding the relay coil on circuit B47. When the relay energizes, its contacts open and disconnect circuits G19 and Z1. Circuit A20 from fuse 4 in the fuse block supplies power to the coil side of the relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4346 Brake Warning Indicator: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION The RWAL module provides ground for the instrument cluster Check Antilock warning lamp on circuit B102. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 4347 Brake Warning Indicator: Testing and Inspection 1. Raise and support vehicle, then open a wheel cylinder bleeder valve. 2. Press down on brake pedal and observe brake warning lamp. If lamp fails to illuminate, inspect for the following: a. Faulty bulb. b. Disconnected electrical socket. c. A broken or disconnected wire at the switch, located in the brake line "T" fitting, mounted on frame rail in engine compartment below master cylinder. 3. On models with diesel engine, brake lamp is also connected to a sensor which monitors vacuum in brake booster system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Cigarette Lighter: Electrical Diagrams Horn/Cigar Lighter NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 4369 Cigarette Lighter: Description and Operation CIRCUIT OPERATION In the ACCESSORY or RUN position, the ignition switch supplies voltage to fuse 9 in the fuse block on circuit A31. Fuse 9 feeds circuit X22 which connects to the cigar lighter. When the lighter is depressed, the contacts inside of the lighter element close and voltage flows to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 4370 Cigarette Lighter: Testing and Inspection In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from Power Distribution Center (PDC) with circuit A31. Circuit A1 is protected by fuse C. Circuit Z1 terminates at the instrument panel lower right reinforcement support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4376 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Page 4380 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Locations Emissions Maintenance Light: Locations Fig. 1 SRI Lamp Location The lamp is displayed on the instrument panel as the MAINT REQ'D lamp Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Locations > Page 4384 Emissions Maintenance Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit G5 from fuse 16 in the fuse block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G1 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation CIRCUIT OPERATION Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. The fuel level sensor draws voltage through the fuel gauge on circuit G4. The fuel level sensor is located in the fuel tank. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit Z1 provides the ground path for the fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 4391 Fuel Gauge: Testing and Inspection 1. Place ignition switch in On position, then disconnect fuel gauge sending unit connector at top of tank and observe gauge. Needle should move to or remain at low end of scale. 2. Connect a jumper wire between sending unit ground cavity and gauge input cavity in body half of sending unit connector and observe gauge. Needle should move to high end of scale. 3. If needle performs as specified, replace fuel gauge sending unit; if not, proceed as follows: a. Remove jumper wire and place ignition switch in Off position, then disconnect battery ground cable. b. Check for continuity between sending unit ground cavity in body half of sending unit connector and ground. If continuity exists, continue with procedure; if not, repair ground circuit as necessary. c. Remove instrument cluster and bezel, then disconnect printed circuit No. 1 connector 1 and probe connector cavity H for continuity to ground. If continuity exists, repair short as necessary; if not, continue with procedure. d. Check for continuity between cavity H and gauge input cavity of sending unit body half connector. If continuity exists, replace fuel gauge; if not, repair open circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4397 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Relay > Component Information > Locations Key Reminder Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Relay > Component Information > Locations > Page 4401 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Relay > Component Information > Locations > Page 4402 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Relay > Component Information > Locations > Page 4403 Key Reminder Relay: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch lamp and the courtesy lamp. Power for the relay is received on the M1 circuit from the IOD fuse in cavity 2 in the Power Distribution Center (PDC). Circuit M2 provides ground for the time delay relay through the right and left door jamb switches and the headlamp switch. When a door is opened or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on circuit M2. This energizes the relay, causing the contacts to close. When the relay contacts close, power is provided through the relay to circuit M50. The M50 circuit supplies current to the ignition key-in switch lamp and the courtesy lamp. Circuit Z1 provides ground for the lamps. Circuit Z1 also provides ground for the ash receiver lamp and the cigar lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Relay > Component Information > Locations > Page 4404 Key Reminder Relay: Testing and Inspection Circuit M1 splices to supply voltage to the glove box lamp, dome lamp, overhead console, power mirror switch, and radio. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation OPERATION The Powertrain Control Module (PCM) performs an on-board Diagnostic (OBD) check of the EGR system on all California vehicles. The diagnostic system uses the electronic EGR Transducer (EET) for the system tests. The OBD check activates only during selected engine/driving conditions. When the conditions are met, the PCM energizes the EET solenoid to disable the EGR. the PCM checks for a change in the oxygen sensor signal. If the air/fuel mixture goes lean, the PCM will attempt to enrich the mixture. The PCM registers a Diagnostic Trouble Code (DTC) if the EGR system has failed or degraded. After registering a DTC, the PCM turns the Malfunction Indicator Lamp (MIL) ON. The MIL indicates the need for immediate service. If a malfunction is indicated by the MIL and a DTC for the EGR system was set, check for proper operation of the EGR system. If the EGR system tests properly, check the system using the DRB II scan tool. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. The gauge uses two coils. One coil receives fixed current. Circuit G60 connects the other coil to the pressure sensor. As oil pressure changes, the variable resistor in the sensor changes the current flow through the second coil in the gauge. A change in current flow alters the position of the gauge pointer. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Page 4411 Oil Pressure Gauge: Testing and Inspection Actual engine oil pressure should be checked with a test gauge and compared with gauge readings prior to performing gauge diagnostic procedures. 1. Place ignition switch in On position, then disconnect sending unit connector and observe gauge. Needle should move to or remain at low end of scale. 2. Connect a jumper wire between cavity 1 of sending unit connector and ground and observe gauge. Needle should move to high end of scale. 3. If gauge performs as specified, replace sending unit; if not, proceed as follows: a. Remove jumper wire and place ignition switch in Off position, then disconnect battery ground cable and remove instrument cluster and bezel. b. Disconnect gray connector from righthand side of cluster, then probe connector cavity K for continuity to ground. If continuity exists, repair short as necessary; if not, continue with procedure. Fig. 5 Oil Pressure Sending Unit Connector Terminal Identification c. Check for continuity between cavity 1 of sending unit wire connector, and gray cluster connector cavity K. If continuity exists, replace oil pressure gauge; if not, repair open circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 4415 Oil Pressure Warning Lamp/Indicator: Testing and Inspection The Low Oil Pressure lamp will illuminate when the ignition key is turned to the On position. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. 1. Turn ignition key to On position. 2. If lamp fails to illuminate, check for the following conditions: a. A broken or disconnected wire at the oil pressure combination unit, located at rear of engine. b. If wire is satisfactory, pull connector loose from switch and connect a jumper wire from ground to engine. c. If lamp does not illuminate with ignition switch in On position, inspect for a faulty bulb or disconnected socket in the instrument cluster. 3. If lamp illuminates, start engine. If lamp remains on, immediately stop engine and check oil pressure with a test gauge. If oil pressure is satisfactory, check for a grounded wire and/or replace oil pressure sending unit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation Outside Temperature Display Sensor: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 4423 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation CIRCUIT OPERATION Ground for the park brake lamp is supplied through the case grounded park brake switch on circuit G11. If the vehicle is equipped with Rear Wheel Antilock (RWAL) brakes, circuit 011 provides an input to the Controller, Antilock Brakes (CAB) and splices to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 4431 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Page 4432 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation Audible Warning Device Control Module: Description and Operation CIRCUIT OPERATION The buzzer module sounds an audible warning tone. The tone sounds for seat belt warning and when the ignition key is in the ignition switch while the drivers door is open. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled. Fuses 7 and 16 in the fuse block protect the buzzer module. Fuse 7 powers circuit F32 which connects to the buzzer module. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies power to the fuse block for fuse 7 and circuit F32. Circuit G5 from fuse 16 in the fuse block also provides voltage to the buzzer module when the ignition switch is in the START or RUN positions. The ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 connects to the fuse block. When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26 connects to the buzzer module and the key-in switch. Circuit G16 from the drivers side door jamb switch also connects to the key-in switch. Circuit G13 from the buzzer powers the seat belt warning lamp in the instrument cluster. Circuit Z1 at the instrument cluster provides ground for the lamp. Circuit G1O from the buzzer connects to the seat belt switch. When the seat belt switch closes a path to ground is completed on circuit Z1. Circuit Z1 also grounds the combination buzzer module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 4437 Audible Warning Device Control Module: Testing and Inspection - Circuit F32 also powers the stop lamp switch. - Circuit G5 is double crimped at the buzzer module. The G5 branch from the buzzer module splices to power the four-wheel drive lamp and the overdrive lamp, and transmission temperature warning lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations Key Reminder Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 4441 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 4442 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 4443 Key Reminder Relay: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch lamp and the courtesy lamp. Power for the relay is received on the M1 circuit from the IOD fuse in cavity 2 in the Power Distribution Center (PDC). Circuit M2 provides ground for the time delay relay through the right and left door jamb switches and the headlamp switch. When a door is opened or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on circuit M2. This energizes the relay, causing the contacts to close. When the relay contacts close, power is provided through the relay to circuit M50. The M50 circuit supplies current to the ignition key-in switch lamp and the courtesy lamp. Circuit Z1 provides ground for the lamps. Circuit Z1 also provides ground for the ash receiver lamp and the cigar lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 4444 Key Reminder Relay: Testing and Inspection Circuit M1 splices to supply voltage to the glove box lamp, dome lamp, overhead console, power mirror switch, and radio. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The seat belt indicator warning lamp is activated by the combination buzzer on circuit G13. Circuit G13 supplies power to instrument cluster for the lamp. Circuit Z1 provides ground for the lamp. The Z1 circuit terminates a the instrument panel right lower reinforcement support. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 4452 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation Outside Temperature Display Sensor: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch Rear Wheel Antilock Brakes CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. All Wheel Antilock Brakes CIRCUIT OPERATION Circuit G9 from the Controller, Anti-Lock Brakes (CAB), provides ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Brake Warning Lamp Switch > Page 4460 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 4461 Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A41 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation CIRCUIT OPERATION The speedometer and odometer receive a signal from the vehicle speed sensor on circuit G7. Circuit G7 also connects to the Powertrain Control Module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation CIRCUIT OPERATION The tachometer module in the instrument cluster operates the tachometer. The Powertrain Control Module (PCM) signals the tachometer module on circuit G21. The PCM provides engine speed information to the tachometer module. Circuit Z1 provides ground for the tachometer module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 4468 Tachometer: Testing and Inspection 1. With engine running, check for tachometer signal at PCM connector C (gray).If signal is not present, test or replace PCM; if signal is present, continue with procedure. 2. Disconnect battery ground cable and PCM connector, then remove instrument cluster and bezel assembly and disconnect connector at lefthand side of cluster. 3. Probe the tach signal circuit cavity on left connector for continuity to ground. If continuity exists, repair short as necessary; if not, continue with procedure. 4. Check for continuity between the tach signal cavity of the connector and PCM connector cavity. If continuity exists, continue with procedure; if not, repair open as necessary. 5. Replace tachometer drive module with a known good module, then test vehicle for proper tachometer operation. If tachometer now functions properly, install new module permanently; if not, replace tachometer. 6. If tachometer needle does not return to 0 when ignition switch is placed in Off position, check for battery voltage at the fused B(+) circuit cavity of the left instrument cluster connector and repair open circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION Circuit G20 connects the engine coolant temperature gauge to the engine coolant temperature sensor. The sensor is a variable resistor and case grounded to the engine. As current flows through the coils in the gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the temperature gauge on circuit G20. A change in temperature changes the resistance in the sensor, which alters the current flow through the second coil in the gauge. A change in current flow alters the magnetic field in the gauge, which changes the pointer position. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 4472 Temperature Gauge: Testing and Inspection Engine coolant temperature should be measured with a thermometer and compared to gauge reading prior to performing gauge diagnostic procedures. If it is determined that actual coolant temperature does not match gauge indication, proceed as follows: 1. Place ignition switch in On position, then disconnect coolant temperature sending unit connector and observe gauge; needle should drop to lowest position on scale. If gauge does not perform as specified, continue with procedure. If not, proceed as follows: a. Connect a suitable jumper wire between sending unit wiring and ground and observe gauge; needle should move to highest position on scale. b. If gauge performs as specified, replace sending unit; if not, continue with procedure. 2. Place ignition switch in Off position and disconnect battery ground cable, then remove instrument cluster and bezel. 3. Probe cavity J of printed circuit No. 1 connector to determine if there is continuity to a good ground source; no continuity should exist. If there is continuity, repair short in circuit as necessary. 4. Check for continuity between cavity J and sending unit wiring connector. If continuity exists, replace gauge; if not, repair open in circuit as necessary. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit Al from fuse C in the Power Distribution Center (PDC) with circuit A21. Circuit A21 powers fuse 16 in the fuse block. Fuse 16 protects circuit G5. Circuit G5 supplies voltage to the transmission oil temperature lamp. The Powertrain Control Module (PCM) provides ground for the lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection This diagnostic procedure is not valid unless the voltmeter is the only instrument that is inoperative. If all gauges are inoperative or are not functioning properly, instrument cluster printed circuit must be serviced. 1. Place ignition switch in On position and observe voltmeter, then test voltage at battery using a test voltmeter. 2. If vehicle voltmeter indication is not within 0.6 volts of actual battery voltage, replace voltmeter. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Stop Lamp and CHMSL Lamp Brake Lamp: Description and Operation Stop Lamp and CHMSL Lamp CIRCUIT OPERATION Circuit A3 from fuse G in the power distribution center (PDC) supplies voltage to circuit F32 through fuse 7 in the fuse block. Circuit F32 connects to the stop lamp switch. When the operator depresses the brake pedal, the stop lamp switch closes and connects circuit F32 to circuit L50. Circuit L50 connects to the Center High Mounted Stop Lamps (CHMSL) and multi-function switch. The multi-function switch supplies power to the L62 and L63 circuits. Circuit L62 powers the right stop lamp. Circuit L63 powers the left stop lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Stop Lamp and CHMSL Lamp > Page 4488 Brake Lamp: Description and Operation Stop Lamp Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the stop lamps, back-up lamps and CHMSL lamps. The Z1 circuit has more than one branch. Circuit Z1 also supplies ground path for the tail lamps, parking lamps, side marker lamps, rear license plate lamp, back-up lamps, and turn signals. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Page 4489 Brake Lamp: Testing and Inspection - Check for blown fuse in circuit F32. - Check for continuity across the stop lamp switch when it is closed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes Brake Light Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29, the Controller, Anti-Lock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 connects to cavity 9 of the CAB, the stop lamp switch and the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 4494 Brake Light Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 4495 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column opening cover. 3. Remove screws attaching air duct to air conditioning/defroster and move to gain access to switch bracket. 4. Unseat wire harness retainer from pedal support and remove retainer, then remove switch bracket nut and washer. 5. Push brake pedal forward then work switch and bracket out of support. 6. Disconnect switch wires, then remove switch and bracket as assembly. 7. Reverse procedure to install, noting the following: a. Torque bracket retaining nut to 60 inch lbs. b. Ensure bracket tang seats in support. c. Check switch operation before attaching air duct and steering column cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Description and Operation > Ground Circuit Center High Mounted Stop Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the stop lamps, back-up lamps and CHMSL lamps. The Z1 circuit has more than one branch. Circuit Z1 also supplies ground path for the tail lamps, parking lamps, side marker lamps, rear license plate lamp, back-up lamps, and turn signals. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Description and Operation > Ground Circuit > Page 4500 Center High Mounted Stop Lamp: Description and Operation Stop Lamp and CHMSL Lamp CIRCUIT OPERATION Circuit A3 from fuse G in the power distribution center (PDC) supplies voltage to circuit F32 through fuse 7 in the fuse block. Circuit F32 connects to the stop lamp switch. When the operator depresses the brake pedal, the stop lamp switch closes and connects circuit F32 to circuit L50. Circuit L50 connects to the Center High Mounted Stop Lamps (CHMSL) and multi-function switch. The multi-function switch supplies power to the L62 and L63 circuits. Circuit L62 powers the right stop lamp. Circuit L63 powers the left stop lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Description and Operation > Page 4501 Center High Mounted Stop Lamp: Testing and Inspection - Check for blown fuse in circuit F32. - Check for continuity across the stop lamp switch when it is closed. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation Glove Box Lamp: Description and Operation CIRCUIT OPERATION Circuit M1 from the Ignition Off Draw (IOD) fuse in cavity 2 in the Power Distribution Center (PDC) powers the glove box lamp. A case grounded switch, in series after the lamp, closes when the glove box door is opened. The switch completes a path to ground. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position. When the ignition switch is in the RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC), to circuit A21. Circuit A21 is double crimped at a fuse block bus bar and supplies power to the Daytime Running Module (DRL) module. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times. The DRL module receives the vehicle speed sensor input from circuit G7. Circuit G34 provides power for the high beam indicator lamp in the instrument cluster and connects to the DRL module. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page 4513 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Description and Operation Dome Lamp: Description and Operation CIRCUIT OPERATION Circuit M1 from the Ignition Off Draw (IOD) fuse in cavity 2 in the Power Distribution Center (PDC) supplies power to the dome lamp. This circuit is HOT at all times. The ground path for the lamp is provided in two different ways. One way is through the door jamb switches. Circuit M2 connects to the door jamb switches from the dome lamp. The switches are case-grounded to the body. When a door is opened, the plunger in the switch closes, completing a path to ground. The second ground path is through the headlamp switch. Circuit M2 is spliced in with the headlamp switch. When the operator turns the headlamp switch to the dome lamp ON position, a ground path is provided through the switch. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Fog Lamp Fog/Driving Lamp: Description and Operation Fog Lamp CIRCUIT OPERATION The fog lamps are controlled by the fog lamp switch, park lamp relay and high beam relay. The fog lamps operate only when the headlamp switch is in the ON position, and the operator has selected low-beam operation. When the headlamps are in high-beam operation, the fog lamps will not operate. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies voltage to circuit F39 through fuse 20 in the fuse block. Circuit F39 splices to supply power to the contact side of the park lamp relay. Circuit L7 supplies power to the coil side of the park lamp relay. Circuit L35 connects to the coil side of the relay and to circuit Z1 through the fog lamp switch. Ground for the coil side of the relay is provided on circuit Z1 through the fog lamp switch. When the fog lamp switch closes, the park lamp relay contacts close connecting circuits F39 and L36. Circuit L36 powers the contact side of the high beam relay. When the headlamp high beams are off, the high beam relay is not energized and voltage flows through the normally closed contacts to circuit L39. Circuit L39 supplies voltage to the fog lamps and the illumination lamp in the fog lamp switch. Circuit Z1 provides ground for the fog lamps. If the high beam lamps are on, circuit L3 from the headlamp switch energizes the high beam relay When the high beam relay energizes, the contacts open and power is not supplied to the fog lamps. Circuit Z1 provides ground for the coil side of the high beam relay. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Fog Lamp > Page 4521 Fog/Driving Lamp: Description and Operation Off Road Lamps CIRCUIT OPERATION Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies voltage to circuit F39 through fuse 20 in the fuse block. Circuit F39 splices to supply power to the off-road lamp switch. When the off road lamp switch closes, circuit F39 powers the illumination lamp in the switch and circuit L31. Circuit L31 feeds the off-road lamps. Circuit Z1 provides ground for the off-road lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Page 4522 Fog/Driving Lamp: Testing and Inspection Circuit L3 powers the high beam circuit of the headlamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations Hazard Warning Flasher: Component Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations > Page 4528 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations > Page 4529 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Component Locations > Page 4530 Hazard Warning Flasher: Fuse and Fusible Link Locations Hazard and turn signal flashers are located in fuse panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Ground Circuit Hazard Warning Flasher: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the parking lamps, turn/tail/stop lamps, and rear license plate lamps. Circuit Z1 also provides a ground for the back-up lamps and Center High Mounted Stop Lamps (CHMSL). Circuit Z1 also provide ground for the indicator lamps, and side marker lamps at the left inner fender panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Ground Circuit > Page 4533 Hazard Warning Flasher: Description and Operation Hazard Flasher CIRCUIT OPERATION Circuit A15 from the battery positive post supplies power to the hazard flasher fuse in cavity one in the Power Distribution Center (PDC). Circuit A15 has an in-line fusible link. Circuit L9 from the hazard flasher fuse supplies battery voltage to the hazard warning flasher. Circuit L19 from the flasher connects to the multi-function switch. When the operator depress the hazard flasher button, the multi-function switch connects circuit L19 to circuits L60, L61, L62, and L63. Circuit L62 powers the right rear turn signal/stop lamp. Circuit L63 powers the left rear turn signal/stop lamp. Circuit L60 powers the right indicator lamp. Circuit L61 powers the left indicator lamp. Circuit L60 also splices to feed the instrument cluster right indicator lamp. Circuit L61 splices to feed the instrument cluster left indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 4534 Hazard Warning Flasher: Testing and Inspection Check the fusible link in the A15 circuit. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position > Page 4540 Headlamp Switch: Description and Operation Headlamp Switch in the PARKING LAMP Position CIRCUIT OPERATION Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker that connects circuit A3 to circuit L20. In the OFF and PARK positions, the headlamp switch feeds circuit L20 which connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L20 to circuit L3. Circuit L3 feeds the high beam of the headlamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 4541 Headlamp Switch: Service and Repair 1. Disconnect ground cable from battery. Steering Column Cover 2. Remove lower cover and instrument cluster bezel. 3. Remove five switch bezel screws, then pull switch and bezel assembly to rear and disconnect wiring. 4. Remove and discard nut, then push release button on right side of switch and pull headlamp knob out. 5. Separate bezel from switch and mounting assembly, then remove spanner nut and remove headlamp switch from mounting bracket. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation CIRCUIT OPERATION Circuit L3 from the headlamps dimmer switch feeds the high beams of the headlamps and splices to circuit G34. Circuit G34 supplies power for the high beam indicator lamp. The ground path for the lamp is through circuit Z1 Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 4549 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 4550 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation Key Cylinder Lamp: Description and Operation CIRCUIT OPERATION Circuit M50 from the time delay relay supplies voltage to the courtesy lamp and the ignition switch lamp. Circuit Z1 provides ground for both lamps. Circuit M1 supplies volt Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Ground Circuit License Plate Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the parking lamps, tail lamps, and rear license plate lamps. There are two different license plate lamp systems; a one lamp system or a two lamp system. If the vehicle is not equipped with a step bumper, it has the one lamp system. If the vehicle has a step bumper, it uses the two lamp license plate lamp system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Ground Circuit > Page 4561 License Plate Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp CIRCUIT OPERATION Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to the headlamp switch. Fuse G in the PDC protects the A3 circuit. Fuse 8 in the fuse block protects circuit F33. The headlamp switch has three positions: ON, PARK (parking lamps) and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamps Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Page 4562 License Plate Lamp: Testing and Inspection - If the vehicle is equipped with factory installed fog lamps, circuit L7 splices to feed the park lamp relay. - Check fuse G in PDC. - Check fuse 8 in the fuse block. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 in the fuse block protects circuits E1 and E2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Ground Circuit Parking Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the parking lamps, tail lamps, and rear license plate lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Ground Circuit > Page 4567 Parking Lamp: Description and Operation Parking Lamp CIRCUIT OPERATION Circuit A3 from fuse G in the Power Distribution Center (PDC) powers circuit F33 through fuse 8 in the fuse block. Circuit F33 connects to the headlamp switch. The headlamp switch has three positions: ON, PARK (parking lamps) and OFF, plus a dimmer switch. when the headlamp switch is in the PARK or ON position, it connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Page 4568 Parking Lamp: Testing and Inspection - If the vehicle is equipped with factory installed fog lamps, circuit L7 splices to feed the coil side of the park lamp relay. - Check fuse G in PDC. - Check fuse 8 in the fuse block. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 in the fuse block protects circuits E1 and E2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position. When the ignition switch is in the RUN position, it connects circuit A1 from fuse C in the Power Distribution Center (PDC), to circuit A21. Circuit A21 is double crimped at a fuse block bus bar and supplies power to the Daytime Running Module (DRL) module. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times. The DRL module receives the vehicle speed sensor input from circuit G7. Circuit G34 provides power for the high beam indicator lamp in the instrument cluster and connects to the DRL module. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 4576 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 4577 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes Brake Light Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29, the Controller, Anti-Lock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 connects to cavity 9 of the CAB, the stop lamp switch and the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > All Wheel Antilock Brakes > Page 4589 Brake Light Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION - Stop Lamp Switch Sense On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 4590 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column opening cover. 3. Remove screws attaching air duct to air conditioning/defroster and move to gain access to switch bracket. 4. Unseat wire harness retainer from pedal support and remove retainer, then remove switch bracket nut and washer. 5. Push brake pedal forward then work switch and bracket out of support. 6. Disconnect switch wires, then remove switch and bracket as assembly. 7. Reverse procedure to install, noting the following: a. Torque bracket retaining nut to 60 inch lbs. b. Ensure bracket tang seats in support. c. Check switch operation before attaching air duct and steering column cover. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In ON Position > Page 4595 Headlamp Switch: Description and Operation Headlamp Switch in the PARKING LAMP Position CIRCUIT OPERATION Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker that connects circuit A3 to circuit L20. In the OFF and PARK positions, the headlamp switch feeds circuit L20 which connects to the multi-function switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L20 to circuit L3. Circuit L3 feeds the high beam of the headlamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 4596 Headlamp Switch: Service and Repair 1. Disconnect ground cable from battery. Steering Column Cover 2. Remove lower cover and instrument cluster bezel. 3. Remove five switch bezel screws, then pull switch and bezel assembly to rear and disconnect wiring. 4. Remove and discard nut, then push release button on right side of switch and pull headlamp knob out. 5. Separate bezel from switch and mounting assembly, then remove spanner nut and remove headlamp switch from mounting bracket. 6. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Page 4600 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Ground Circuit Tail Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides a ground for the parking lamps, tail lamps, and rear license plate lamps. There are two different license plate lamp systems; a one lamp system or a two lamp system. If the vehicle is not equipped with a step bumper, it has the one lamp system. If the vehicle has a step bumper, it uses the two lamp license plate lamp system. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Ground Circuit > Page 4605 Tail Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp CIRCUIT OPERATION Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to the headlamp switch. Fuse G in the PDC protects the A3 circuit. Fuse 8 in the fuse block protects circuit F33. The headlamp switch has three positions: ON, PARK (parking lamps) and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamps Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Page 4606 Tail Lamp: Testing and Inspection - If the vehicle is equipped with factory installed fog lamps, circuit L7 splices to feed the park lamp relay. - Check fuse G in PDC. - Check fuse 8 in the fuse block. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 in the fuse block protects circuits E1 and E2. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Fuse/Fuse Block (Part 1 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 4611 Fuse/Fuse Block (Part 2 Of 3) Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 4612 Fuse/Fuse Block (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation CIRCUIT OPERATION Circuits L61 and L60 power the turn signal indicator lamps. Circuit L61 powers the left indicator lamp. Circuit L60 powers the right indicator lamp. Circuit Z1 provides ground for the lamps. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Page 4619 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Description and Operation Underhood Lamp: Description and Operation CIRCUIT OPERATION Circuit M1 from the Ignition Off Draw (IOD) fuse in cavity 2 in the Power Distribution Center supplies battery voltage for the underhood lamp. A mercury switch, in series after the lamp, connects the lamp to ground on circuit Z1. When the hood is raised, mercury inside the switch moves to a position where it connects circuit M1 to ground circuit Z1, illuminating the lamp. The underhood lamp is wired in parallel with other components on circuit M1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation Power Window Switch: Description and Operation Driver Side Switch Operation CIRCUIT OPERATION Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation > Page 4629 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 4630 Power Window Switch: Testing and Inspection - Check fuse E in the PDC. - Check the circuit breaker in cavity 2 of the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation Power Window Switch: Description and Operation Driver Side Switch Operation CIRCUIT OPERATION Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Driver Side Switch Operation > Page 4636 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Page 4637 Power Window Switch: Testing and Inspection - Check fuse E in the PDC. - Check the circuit breaker in cavity 2 of the fuse block. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair DOOR GLASS REMOVAL 1. Remove the door trim panel (or, if applicable, the access panel), the waterdam and the noise insulator. 2. Open the window glass (move the glass down into the door). Door Beltline Moulding Weatherstrip 3. Remove the retaining screws and the beltline weatherstrip moulding from the door. CAUTION: Damage to the window glass rear track channel is possible it the glass is removed without using Tool C-4867 (or an equivalent tool). Door Window Glass Removal/Installation 4. Use Tool C-4867 to disengage the window glass edge sliders from the glass rear track. 5. Rotate the window glass on the regulator roller, slide it rearward and upward at a 45° angle, and remove it from the door. INSTALLATION 1. Install replacement edge sliders on the window glass rear edge. 2. Insert the window glass into the door. 3. Slide it forward and downward at a 45° angle. 4. Engage the window glass edge sliders with the glass rear track. 5. Engage the lift channel with the regulator roller. 6. Position the beltline weatherstrip moulding on the door panel and install the retaining screws. Tighten the screws securely 7. Install the noise insulator, the waterdam and the door trim panel (or, if applicable, the access panel). Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair Window Regulator: Service and Repair Regulator Removal/Installation REGULATOR REMOVAL 1. Remove the door trim panel (or, if applicable, the access panel), the waterdam, and the noise insulator. 2. Remove window glass. 3. After the glass is removed from the door, remove the retaining blind rivets with a drill and remove the lift channel from the glass. 4. If necessary remove the retaining screws and remove the glass rear channel/track from the door. 5. Remove the window glass regulator retaining screws. 6. Remove the window glass regulator from the door. INSTALLATION 1. If removed, position the glass rear channel/track in the door and install the retaining screws. Tighten the screws securely 2. Install the lift channel and gaskets on the window glass with 1/4-20 x 1/2" bolts and nuts. Tighten the nuts to 10 Nm (90 in. lbs.) torque. 3. Install replacement edge sliders on the window glass rear edge. 4. Position the window glass regulator in the door and install the retaining screws. Tighten the screws securely 5. Install the window glass in the door. 6. Install the door trim panel (or, if applicable, the access panel), the waterdam, and the noise insulator. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 232696 > Apr > 96 > A Pillar - Popping/Scratching Noise Windshield: Customer Interest A Pillar - Popping/Scratching Noise NO: 23-26-96 GROUP: Body DATE: Apr. 12, 1996 SUBJECT: Popping/Scratching Noise Coming From The A-Pillar Area MODELS: 1996 (AN) Dakota SYMPTOM/CONDITION: Customers may complain of a popping noise (during cold ambient temperatures) or scratching noise (during warm ambient temperatures) coming from the A-Pillar area while driving the vehicle. DIAGNOSIS: Drive the vehicle on a rough surface road. Perform the following Repair Procedure if either of the above conditions are identified near the driver or passenger A-Pillar area. PARTS REQUIRED: 1 4773427 Mopar Weatherstrip Lubricant REPAIR PROCEDURE: This bulletin involves applying weatherstrip lubricant to both right and left A-Pillar Mylar windshield molding. 1. Allow the vehicle body temperature to reach a minimum of 4.4°C (40°F). 2. Beginning at the top of the A-Pillar, use a trim stick and gently lift the outboard edge of the windshield molding. 3. Apply a sufficient amount of Mopar weatherstrip lubricant to coat the molding contact surfaces in the channel until the windshield molding is lubricated from the top of the A-Pillar to the bottom of the A-Pillar. 4. Allow at least one hour for the lubricant to work its way into the windshield molding Mylar material before returning the vehicle to the customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-65-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232696 > Apr > 96 > A Pillar - Popping/Scratching Noise Windshield: All Technical Service Bulletins A Pillar - Popping/Scratching Noise NO: 23-26-96 GROUP: Body DATE: Apr. 12, 1996 SUBJECT: Popping/Scratching Noise Coming From The A-Pillar Area MODELS: 1996 (AN) Dakota SYMPTOM/CONDITION: Customers may complain of a popping noise (during cold ambient temperatures) or scratching noise (during warm ambient temperatures) coming from the A-Pillar area while driving the vehicle. DIAGNOSIS: Drive the vehicle on a rough surface road. Perform the following Repair Procedure if either of the above conditions are identified near the driver or passenger A-Pillar area. PARTS REQUIRED: 1 4773427 Mopar Weatherstrip Lubricant REPAIR PROCEDURE: This bulletin involves applying weatherstrip lubricant to both right and left A-Pillar Mylar windshield molding. 1. Allow the vehicle body temperature to reach a minimum of 4.4°C (40°F). 2. Beginning at the top of the A-Pillar, use a trim stick and gently lift the outboard edge of the windshield molding. 3. Apply a sufficient amount of Mopar weatherstrip lubricant to coat the molding contact surfaces in the channel until the windshield molding is lubricated from the top of the A-Pillar to the bottom of the A-Pillar. 4. Allow at least one hour for the lubricant to work its way into the windshield molding Mylar material before returning the vehicle to the customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-65-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Intermittent Wipe Module Remove/Install The Intermittent Wiper Control Unit is located to the right of the steering column on the back side of the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation CIRCUIT OPERATION Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster. When the low washer fluid switch closes, it connects circuits G29 and Z1. Circuit Z1 provides a ground path, illuminating the warning lamp. Circuit Z1 also provides ground for the windshield washer pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Page 4680 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Two Speed Wiper Switch Continuity Chart Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 4684 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 4685 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation CIRCUIT OPERATION Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster. When the low washer fluid switch closes, it connects circuits G29 and Z1. Circuit Z1 provides a ground path, illuminating the warning lamp. Circuit Z1 also provides ground for the windshield washer pump motor. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Page 4692 Multifunction Switch 7. Loosen connector screws and disconnect wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque multi-function switch connector and retaining screws 17 inch lbs. b. Torque steering column upper bracket nuts 110 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Intermittent Wipe Module Remove/Install The Intermittent Wiper Control Unit is located to the right of the steering column on the back side of the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair Wiper Motor: Service and Repair 1. Disconnect battery ground cable, then disconnect wiper motor electrical connector. 2. Remove three motor attaching nuts and wiper arms. 3. Remove cowl screen screws, then disengage grille rear from windshield weatherstrip by pulling forward and remove grille panel. 4. Carefully pry grille screen clips and remove grille. 5. Hold drive crank with a wrench and remove crank nut, then remove drive crank from motor shaft. 6. Remove wiper motor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque motor mounting nuts to 65 inch lbs. b. Torque motor crank arm nut to 95 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Two Speed Wiper Switch Continuity Chart Dodge Dakota 2wd Workshop Manual (V6-239 3.9L Magnum (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 4715 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. Steering Column Cover 3. Remove lower cover. Steering Column 4. Remove upper and lower lock covers from column, then lower fixed column cover. 5. Loosen steering column upper bracket nuts, but do not remove. Move upper fixed column cover to gain access to rear of multi-function switch. 6. Remove multi-function switch mounting screws with Snap On torx tool No. TTXR20B2, or equivalent, then gently pull switch away from column.